Method for electron beam additive manufacturing of pure copper heat dissipation part special for new energy automobile
Through electron beam additive manufacturing and surface modification technology, combined with high thermal conductivity pure copper material, designing a radiator with complex structures, solving the problem that traditional technology is difficult to prepare complex copper components, and achieving efficient heat dissipation and surface of new energy vehicle parts Fine treatment improves heat dissipation rate and surface accuracy.
Patent Information
- Application Number
- CN202411091746.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-09
- Publication Date
- 2025-01-10
AI Technical Summary
It is difficult to prepare complex and efficient radiators, especially those made of copper, which have problems such as high powder cost, low copper absorption rate on red lasers, and high internal stress on components, which limit the development of radiators in new energy vehicles.
Using electron beam additive manufacturing technology, combined with surface modification technology, the dot matrix structure and follow-up cooling runner structure are designed, and the high-thermal conductivity of pure copper materials can be used to achieve the tempering treatment of parts through preheating strategies to prevent oxidation and quickly Made complex cavity structures and use plasma electropolishing technology for surface finishing.
It realizes efficient heat dissipation of new energy vehicle parts, rapid manufacturing and fine processing of complex structures, improves heat dissipation rate and surface accuracy, reduces powder costs, and solves the problem that traditional technology is difficult to prepare complex copper components.
Abstract
Description
Technical Field
[0001] The present invention belongs to the technical field of new energy vehicles, and in particular relates to a method for manufacturing pure copper heat dissipation components for new energy vehicles by electron beam additive manufacturing. Background Art
[0002] The heat dissipation units of new energy vehicles mainly include power batteries, drive motors and electronic control systems. From the perspective of traditional engine heat dissipation technology and the actual application effects of new energy vehicle heat dissipation, water cooling and air cooling are the two main ways of heat dissipation for new energy vehicles. Among them, the function of the water tank radiator is to cool the coolant entering the chip. In terms of material, it is divided into copper water tank and aluminum water tank. In terms of internal structure, it is divided into plate-fin type, tube-belt type and tube-sheet type. Traditional processing technology makes it difficult to prepare complex radiators, which limits the development of advanced and efficient radiators.
[0003] Additive manufacturing can produce copper parts with complex structures. However, due to the high powder cost of laser additive manufacturing, the low absorption rate of copper to red laser, and the large internal stress of the parts, it is difficult to achieve the integrated forming of complex copper parts. Summary of the invention
[0004] The purpose of the present invention is to provide a method for electron beam additive manufacturing of pure copper heat dissipation components dedicated to new energy vehicles. The method is based on the structural design of a radiator dedicated to new energy vehicles, a pure copper material with high thermal conductivity, an electron beam additive manufacturing technology, and a surface modification technology. The powder cost used in electron beam additive manufacturing is low, copper has high energy absorption of electron beams, and has a fast forming speed. In addition, the tempering treatment of parts can be achieved through a preheating strategy, and pure copper oxidation can be prevented in a high vacuum environment, thereby achieving efficient heat dissipation of new energy vehicle parts, rapid manufacturing of complex inner cavity structures, and fine finishing.
[0005] The objective of the present invention is achieved through the following technical solutions: providing a pure copper heat dissipation component dedicated to new energy vehicles, wherein the pure copper heat dissipation component includes a lattice structure and / or a conformal cooling channel structure, the lattice structure is arranged at the load-bearing part of the pure copper heat dissipation component, the conformal cooling channel structure is arranged at the heat dissipation part of the pure copper heat dissipation component, and the heat dissipation part includes one or more of the thin sheets of plate-fin type, tube-belt type, and tube-fin type radiators; the porosity of the lattice structure is 10-90%, and the aperture of the conformal cooling channel structure is 1.0-3.0 mm.
[0006] Preferably, the pure copper heat dissipation component is manufactured by electron beam additive manufacturing technology.
[0007] Preferably, the pure copper heat dissipation component is prepared by using surface modification technology.
[0008] The present invention also provides a method for electron beam additive manufacturing of pure copper heat dissipation components dedicated to new energy vehicles, comprising the following steps:
[0009] (1) Design a radiator component model and fill the lattice structure and conformal cooling channels into the radiator components, including the chassis radiator, water tank radiator, electronic fan blades, and heat dissipation cover;
[0010] (2) performing model processing and optimization on the three-dimensional data model established in step (1), including hole processing and model internal optimization;
[0011] (3) adjusting the processing position of the optimized model, slicing and layering, editing the scanning path strategy of electron beam preheating and melting of each slice, and generating a data parameter package for the printing process;
[0012] (4) Setting the process parameters for base plate heating, powder preheating and sintering, and part forming;
[0013] (5) Under high vacuum conditions, preheat the pure copper substrate, spread powder, preheat, and melt it, and prepare parts point by point, line by line, surface by surface, and layer by layer to obtain a pure copper heat sink with optimized structure;
[0014] (6) After printing is completed, the furnace cools down until the bottom plate temperature is below 50-80°C, then the air valve is opened and the parts are taken out;
[0015] (7) Place the parts into a powder recovery system to remove excess powder from the processed parts;
[0016] (8) Plasma electrolysis technology is used for non-destructive surface finishing to obtain a pure copper radiator with high surface accuracy.
[0017] Preferably, in step (1) of the present invention, the lattice structure is filled in the load-bearing part of the radiator, and its porosity is 10 to 90%, and the aperture of the conformal cooling channel is 1.0 to 3.0 mm, which is mainly distributed on the thin sheets of plate-fin, tube-belt, and tube-fin radiators.
[0018] Preferably, in step (2) of the present invention, the designed part is rotated and placed in combination with the forming capability of the electron beam printing flow channel.
[0019] Preferably, in step (3) of the present invention, the slice thickness is 50-100 μm; the preheating scanning path planning is divided into two steps, the first step is preheating the entire area of the substrate, the scanning strategy is a chessboard, the second step is preheating at 5-10 mm from the outer contour of the part, and the scanning strategy is a circular inward expansion; the melting scanning path planning is divided into four steps, the first step is scanning along the outer contour of the part once, the second step is scanning along the outer contour of the part once with a distance of 20-40 μm inward, the third step is parallel scanning with a scanning spacing of 50-120 μm inside the part, and the fourth step is scanning along the outer contour of the part once. The third step parallel scanning of adjacent slice layers is relatively rotated 90°.
[0020] Preferably, in step (4) of the present invention, the electron beam deflection is calibrated to ensure its precise offset scanning, the scanning defocused beam current is 28 to 45 mA for 8 to 15 s when the substrate is preheated, the defocused current of the powder preheating is 5 to 30 mA for 10 to 35 s, and the scanning focused beam current is 6 to 9 mA during melting, and the scanning speed is 0.25 to 10 m / s.
[0021] Preferably, in step (5) and step (6) of the present invention, the preheating temperature of the pure copper substrate is 250-450°C, the mass fraction of the pure copper powder is 99.5-99.95%, the powder particle size distribution is 53-106 μm, and the vacuum condition is 5×10 -3 ~1×10 - 3 Mpa.
[0022] Preferably, in step (7) of the present invention, the powder recovery system can recycle 90-95% of the unmelted powder and clean out the powder inside the opening.
[0023] Preferably, in step (8) of the present invention, the plasma electropolishing voltage is 180-300 V, the time is 1-2 min, the electrolyte is an aqueous solution of citric acid (C6H8O7), the conductivity of which is 4-30 S / m, and the specific surface area of the anode and the cathode is 1:10.
[0024] Beneficial effects of the present invention:
[0025] The present invention starts with the structural design of the radiator components of new energy vehicles to achieve a certain heat dissipation effect in terms of geometric shape; secondly, it adopts advanced high thermal conductivity material pure copper, and utilizes the advantages of electron beam additive manufacturing to quickly manufacture complex components and high energy utilization rate to solve the manufacturing difficulties of pure copper complex components; finally, it uses advanced plasma electrolytic polishing technology to achieve new energy vehicle radiator components with metallic luster and high precision. DETAILED DESCRIPTION
[0026] The present invention is described in detail below in conjunction with specific implementation modes, but the protection scope of the present invention is not limited to the described contents.
[0027] Example 1
[0028] (1) Design a new energy vehicle chassis radiator component model, fill the lattice structure in the load-bearing part of the radiator, and its porosity is 60%.
[0029] (2) Processing and optimizing the three-dimensional data model established in step 1, including hole processing and internal optimization of the model;
[0030] (3) Adjust the processing position of the optimized model, slice and layer it, and the slice thickness is 50μm; edit the scanning path strategy of electron beam preheating and melting of each slice layer, and generate the data parameter package in the printing process. The first step is to preheat the entire area of the substrate, and the scanning strategy is chessboard. The second step is to preheat 5mm away from the outer contour of the part, and the scanning strategy is a circular shape that expands inward; the melting scanning path planning is divided into four steps. The first step is to scan along the outer contour of the part once, the second step is to scan along the outer contour of the part once with a distance of 20μm inward, the third step is to use parallel scanning with a scanning spacing of 50μm inside the part, and the fourth step is to scan along the outer contour of the part once. The third step of parallel scanning of adjacent slice layers is relatively rotated 90°.
[0031] (4) Set the process parameters for base plate heating, powder preheating and sintering, and part forming. Calibrate the electron beam deflection to ensure accurate offset scanning. When the substrate is preheated, the defocused beam current is 28 mA and the time is 8 s. When the powder is preheated, the defocused current is 5 mA and the time is 10 s. When melting, the focused beam current is 6 mA and the scanning speed is 0.25 m / s.
[0032] (5) In vacuum, 5×10 -3 Mpa, the mass fraction of pure copper powder is 99.5%, and the powder particle size distribution is 53-106μm. The pure copper substrate is preheated to 250℃, powdered, preheated, and melted. The parts are prepared point by point, line by line, surface by surface, and layer by layer to obtain a pure copper chassis radiator with optimized structure.
[0033] (6) After printing, the vacuum is 5×10 -3 Mpa conditions, cool down with the furnace until the bottom plate temperature is below 50℃, open the gas valve, and open the warehouse to take out the parts;
[0034] (7) Place the parts into a powder recovery system to remove excess powder from the processed parts;
[0035] (8) Under the conditions of plasma electrolytic polishing voltage of 180 V, time of 2 min, electrolyte of citric acid (C6H8O7) aqueous solution, conductivity of 4S / m, and specific surface area of anode to cathode of 1:10, plasma electrolysis technology was used for non-destructive surface finishing to obtain a pure copper chassis radiator with high surface accuracy.
[0036] This embodiment obtains a new energy vehicle chassis radiator component with a surface roughness of 0.2 μm, a density of up to 99.5%, a weight reduction of 40%, and a heat dissipation rate increased by 30%.
[0037] Example 2
[0038] (1) Design a new energy vehicle radiator model, fill the conformal cooling channel with an aperture of 1.0 to 3.0 mm on the plate-fin, tube-strip, and tube-sheet thin sheets;
[0039] (2) Processing and optimizing the three-dimensional data model established in step 1, including hole processing and internal optimization of the model;
[0040] (3) Adjust the processing position of the optimized model, slice and layer it, and the slice thickness is 80μm; edit the scanning path strategy of electron beam preheating and melting of each slice layer, and generate the data parameter package in the printing process. The first step is to preheat the entire area of the substrate, and the scanning strategy is chessboard. The second step is to preheat 8mm away from the outer contour of the part, and the scanning strategy is a circular shape that expands inward; the melting scanning path planning is divided into four steps. The first step is to scan along the outer contour of the part once, the second step is to scan along the outer contour of the part once with a distance of 30μm inward, the third step is to use parallel scanning with a scanning spacing of 80μm inside the part, and the fourth step is to scan along the outer contour of the part once. The third step of parallel scanning of adjacent slice layers is relatively rotated 90°.
[0041] (4) Set the process parameters for base plate heating, powder preheating and sintering, and part forming. Calibrate the electron beam deflection to ensure accurate offset scanning. When preheating the substrate, the defocused beam current is 35 mA for 12 seconds, the defocused current for preheating the powder is 25 mA for 20 seconds, and the focused beam current is 8 mA for melting, with a scanning speed of 5 m / s.
[0042] (5) In vacuum, 5×10 -3 Mpa, the mass fraction of pure copper powder is 99.95%, and the powder particle size distribution is 53-106μm. The pure copper substrate is preheated to 350℃, powdered, preheated, and melted. The parts are prepared point by point, line by line, surface by surface, and layer by layer to obtain a pure copper water tank radiator with optimized structure.
[0043] (6) After printing, the vacuum is 5×10 -3 Mpa condition, cool down with the furnace until the bottom plate temperature is below 80℃, open the gas valve, and open the warehouse to take out the parts;
[0044] (7) Place the parts into a powder recovery system to remove excess powder from the processed parts;
[0045] (8) Under the conditions of plasma electrolytic polishing voltage of 200 V, time of 1.5 min, electrolyte of citric acid (C6H8O7) aqueous solution, conductivity of 15 S / m, and specific surface area of anode to cathode of 1:10, plasma electrolysis technology was used for non-destructive surface finishing to obtain a pure copper water tank radiator with high surface accuracy.
[0046] This embodiment obtains a new energy vehicle water tank radiator with a surface roughness of 0.08 μm, a density of up to 99.2%, and a heat dissipation rate increased by 20%.
[0047] Example 3
[0048] (1) Design an electronic fan blade model for new energy vehicles, and fill the blade with a conformal cooling channel with an aperture of 1.0 to 3.0 mm;
[0049] (2) Processing and optimizing the three-dimensional data model established in step 1, including hole processing and internal optimization of the model;
[0050] (3) Adjust the processing position of the optimized model, slice and layer it, and the slice thickness is 100μm; edit the scanning path strategy of electron beam preheating and melting of each slice layer, and generate the data parameter package in the printing process. The first step is to preheat the entire area of the substrate, and the scanning strategy is chessboard. The second step is to preheat 10mm away from the outer contour of the part, and the scanning strategy is a circular shape that expands inward; the melting scanning path planning is divided into four steps. The first step is to scan along the outer contour of the part once, the second step is to scan along the outer contour of the part once with a distance of 40μm inward, the third step is to use parallel scanning with a scanning spacing of 120μm inside the part, and the fourth step is to scan along the outer contour of the part once. The third step of parallel scanning of adjacent slice layers is relatively rotated 90°.
[0051] (4) Set the process parameters for base plate heating, powder preheating and sintering, and part forming. Calibrate the electron beam deflection to ensure accurate offset scanning. When the substrate is preheated, the defocused beam current is 45 mA and the time is 15 s. When the powder is preheated, the defocused current is 30 mA and the time is 35 s. When melting, the focused beam current is 9 mA and the scanning speed is 10 m / s.
[0052] (5) In vacuum, 5×10 -3 Mpa, the mass fraction of pure copper powder is 99.95%, and the powder particle size distribution is 53-106μm. The pure copper substrate is preheated to 450℃, powdered, preheated, and melted. The components are prepared point by point, line by line, surface by surface, and layer by layer to obtain pure copper electronic fan blades with optimized structure.
[0053] (6) After printing, the vacuum is 5×10 -3 Mpa condition, cool down with the furnace until the bottom plate temperature is below 70℃, open the gas valve, and open the warehouse to take out the parts;
[0054] (7) Place the parts into a powder recovery system to remove excess powder from the processed parts;
[0055] (8) Under the conditions of plasma electrolytic polishing voltage of 300 V, time of 1 min, electrolyte of citric acid (C6H8O7) aqueous solution, conductivity of 30 S / m, and specific surface area of anode to cathode of 1:10, plasma electrolysis technology was used for non-destructive surface finishing to obtain pure copper electronic fan blades with high surface accuracy.
[0056] This embodiment obtains an electronic fan blade for a new energy vehicle with a surface roughness of 0.02 μm, a density of up to 99.6%, a weight reduction of 5%, and a heat dissipation rate increase of 30%.
[0057] The invention discloses a method for electron beam additive manufacturing of pure copper heat dissipation components dedicated to new energy vehicles. Starting from the structural design of the radiator components of new energy vehicles, a certain heat dissipation effect is achieved in terms of geometric shape; secondly, advanced high thermal conductivity material pure copper is adopted, and the advantages of electron beam additive manufacturing such as rapid manufacturing of complex components and high energy utilization are utilized to solve the manufacturing difficulties of pure copper complex components; finally, advanced plasma electrolytic polishing technology is used to realize new energy vehicle radiator components with metallic luster and high precision.
[0058] Finally, the above are only some specific embodiments of the present invention, and do not limit the scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made to the technical solution of the present invention without departing from the principle of the present invention, which should be regarded as the protection scope determined by the present invention.
Claims
1. A pure copper heat dissipation component dedicated to new energy vehicles, characterized in that: The pure copper heat dissipation component includes a lattice structure and / or a conformal cooling channel structure, the lattice structure is arranged at the load-bearing part of the pure copper heat dissipation component, and the conformal cooling channel structure is arranged at the heat dissipation part of the pure copper heat dissipation component, and the heat dissipation part includes one or more of the thin sheets of plate-fin type, tube-belt type, and tube-fin type radiators; the porosity of the lattice structure is 10-90%, and the aperture of the conformal cooling channel structure is 1.0-3.0 mm.
2. The pure copper heat dissipation component dedicated to new energy vehicles according to claim 1 is characterized in that: The pure copper heat dissipation component is prepared by electron beam additive manufacturing technology.
3. The pure copper heat dissipation component dedicated to new energy vehicles according to claim 2 is characterized in that: The pure copper heat dissipation component is prepared by adopting surface modification technology.
4. A method for electron beam additive manufacturing of pure copper heat dissipation components for new energy vehicles, characterized in that: The following steps are involved: (1) Design a pure copper heat dissipation component model; (2) Processing and optimizing the three-dimensional data model established in step 1, including hole processing and internal optimization of the model; (3) adjusting the processing position of the optimized model, slicing and layering, editing the scanning path strategy of electron beam preheating and melting of each slice, and generating a data parameter package for the printing process; (4) Setting the process parameters for base plate heating, powder preheating and sintering, and part forming; (5) Under high vacuum conditions, the pure copper substrate is preheated, powdered, preheated, and melted, and components are prepared point by point, line by line, surface by surface, and layer by layer to obtain a pure copper heat sink with optimized structure; (6) After printing is completed, the furnace cools down until the bottom plate temperature is below 50-80°C, then the air valve is opened and the parts are taken out; (7) Place the parts into the powder recovery system to remove excess powder from the processed parts; (8) Plasma electrolysis technology is used for non-destructive surface finishing to obtain a pure copper radiator with high surface accuracy.
5. The method for manufacturing pure copper heat dissipation components by electron beam additive manufacturing for new energy vehicles according to claim 4, characterized in that: In step (5) and step (6), the preheating temperature of the pure copper substrate is 250-450°C, the mass fraction of the pure copper powder is 99.5-99.95%, the powder particle size distribution is 53-106 μm, and the vacuum condition is 5×10 -3 ~1×10 -3 Mpa.
6. The method for manufacturing pure copper heat dissipation components by electron beam additive manufacturing for new energy vehicles according to claim 1, characterized in that: In step (3), the slice thickness is 50-100 μm; the preheating scanning path planning is divided into two steps, the first step is to preheat the entire area of the substrate, the scanning strategy is a chessboard, and the second step is to preheat 5-10 mm away from the outer contour of the part, and the scanning strategy is a circular inward expansion; the melting scanning path planning is divided into four steps, the first step is to scan along the outer contour of the part once, the second step is to scan along the outer contour of the part once with a distance of 20-40 μm inward, the third step is to use a parallel scan with a scanning spacing of 50-120 μm inside the part, and the fourth step is to scan along the outer contour of the part once. The third step parallel scanning of adjacent slice layers is relatively rotated 90°.
7. The method for manufacturing pure copper heat dissipation components by electron beam additive manufacturing for new energy vehicles according to claim 1, characterized in that: In step (4), the electron beam deflection is calibrated to ensure accurate offset scanning. When the substrate is preheated, the scanning defocused beam current is 28 to 45 mA for 8 to 15 s. The powder preheating defocused current is 5 to 30 mA for 10 to 35 s. When melting, the scanning focused beam current is 6 to 9 mA and the scanning speed is 0.25 to 10 m / s.
8. The method for manufacturing pure copper heat dissipation components by electron beam additive manufacturing for new energy vehicles according to claim 1, characterized in that: In step (8), the plasma electropolishing voltage is 180-300 V, the time is 1-2 min, the electrolyte is an aqueous solution of citric acid, the conductivity of which is 4-30 S / m, and the specific surface area of the anode and the cathode is 1:10.