Additive device and method for ultrasonic resonance assisted direct deposition of high-melting-point metal wire

Abstract

The invention relates to a material adding device and method for ultrasonic resonance assisted direct deposition of a high-melting-point metal wire. The device comprises a wire feeding system, a control system, an ultrasonic resonance system, an electromagnetic induction heating device, a three-axis moving device, a substrate preheating device and a shear strain transmission device. For a high-melting-point metal wire, a wire feeding system drives the metal wire to be conveyed downwards along a high-temperature wire feeding pipe, an electromagnetic induction heating device at the lower end of the high-temperature wire feeding pipe softens the metal wire, the metal wire and the wire feeding pipe penetrate through a shear strain transmission device together, and a hollow connecting rod loaded with piezoelectric ceramics transmits ultrasonic vibration to the metal wire; the metal wire is extruded through a shear strain deposition head, and the ultrasonic resonance auxiliary direct deposition process of the metal wire is completed; the control system can adjust the amplitude and frequency of ultrasonic vibration, the electromagnetic induction heating temperature, the wire feeding speed, the substrate preheating temperature and the working frequency of the shear strain device according to actual conditions. According to the device, direct deposition of the high-melting-point metal wire is achieved through electromagnetic induction heating, high-frequency ultrasonic vibration can greatly reduce the flow stress of the material, a large number of dislocations are generated, atomic diffusion is promoted, and metallurgical bonding of adjacent metal units is achieved.

Description

Technical Field

[0001] The present invention relates to the field of additive manufacturing technology, and specifically to an additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires. Background Art

[0002] Additive manufacturing is a method of forming and joining materials, in which the forming and joining of materials are carried out simultaneously or sequentially. The forming and joining of materials are essentially initiated by the sliding of defects such as dislocations in the metal along the slip plane, and the joining involves the mass exchange across the boundary or interface between adjacent domains of the metal. Mass transfer processes such as diffusion or advection mixing promote the fusion of interfaces in the connection. Both forming and joining require energy input to overcome the initial energy barrier and maintain the continuity of these processes. In addition to the energy input used to drive these processes, additional energy can also be used to assist these processes to allow for greater deformation or to accelerate diffusion behavior.

[0003] Currently available metal additive manufacturing processes include laser or electron beam additive manufacturing, polymer binder deposition, ultrasonic additive manufacturing and stir friction welding additive technology; laser and electron beam additive manufacturing melt metal powder or wire along a prescribed path to combine with the parent material to form a molten pool, which then solidifies to form a solid object line by line and layer by layer; polymer binder deposition is a technology that sinters the metal particles together with the binder; ultrasonic additive manufacturing and stir friction welding additive technologies use local friction heat melting and mechanical strain to shape the raw material material and connect it into a solid.

[0004] The ultrasonic resonance assisted deposition (URAD) method combines ultrasonic vibration with additive manufacturing. The metal wire is softened by ultrasonic vibration and tightly bonded to the substrate and the deposited layer through extrusion deformation. Compared with powder bed melting and directed energy deposition, ultrasonic resonance deposition does not need to melt metal wire or powder, but uses ultrasonic vibration to induce metal wire softening and solid connection to achieve "cold" forming; compared with ultrasonic stir friction welding and ultrasonic powder deposition technology, ultrasonic resonance deposition has a higher vibration frequency and smaller amplitude, which can achieve more precise energy input and plastic flow control; ultrasonic vibration has a strain-promoting effect, which can accelerate atomic diffusion and enable metal wire to achieve metallurgical bonding in a cold state.

[0005] Ultrasonic resonance assisted deposition is a newly developed additive manufacturing technology. It has achieved good printing effects on 6061 and 7075 aluminum alloys. However, for high-melting-point metal materials such as titanium alloys, high-temperature alloys, and high-strength steels, the heat generated by ultrasonic vibration alone is not enough to soften these materials and achieve metallurgical bonding.

[0006] Electromagnetic induction heating is a heating method that uses the principle of electromagnetic induction to convert electrical energy into thermal energy. Its basic principle is to generate eddy currents inside the conductor through high-frequency currents, thereby causing the conductor to heat itself; compared with traditional heating methods, electromagnetic induction heating has the advantages of fast heating speed, high efficiency, precise temperature control, and uniform heating. Summary of the invention

[0007] The purpose of the present invention is to address the limitation that it is difficult to soften high-melting-point metal wires by using only ultrasonic resonance-assisted deposition. The present invention provides an additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires. An electromagnetic induction heating device is installed at a distance above the wire delivery outlet to soften the metal wire, assist ultrasonic resonance in breaking and homogenizing the metal wire, extrude the metal wire to deform it and tightly combine it with a substrate and a deposited layer, thereby realizing additive manufacturing of high-melting-point metal wires.

[0008] The technical solution is as follows:

[0009] The device and method for adding materials by ultrasonic resonance-assisted direct deposition of high-melting-point metal wires are characterized by comprising a wire feeding system, a control system, an ultrasonic resonance system, an electromagnetic induction heating device, a three-axis moving device, a substrate preheating device, and a shear strain transfer device;

[0010] The wire feeding system includes a wire feeding motor and a driving device; the wire feeding motor is placed on one side of the driving device to provide power, the pre-tightening rod on one side of the wire feeding driving device acts on the clamping wheel to clamp the metal wire, the motor drives the driving wheel to drive the driven wheel to rotate, and the metal wire is driven downward by friction; the driving device is connected to the Z-axis vertical mounting frame through two transverse connecting rods;

[0011] The ultrasonic resonance system comprises an ultrasonic generator, an ultrasonic transducer, a cylindrical connecting rod, and a ceramic piezoelectric sheet; the ultrasonic generator is mounted on a Z-axis transverse mounting frame and is used to convert electrical energy into a high-frequency alternating current signal that matches the ultrasonic transducer; the ultrasonic transducer is fixed on the cylindrical connecting rod and is connected to the ultrasonic generator through a wire; the right side of the cylindrical connecting rod is connected to the Z-axis transverse mounting frame, the cylindrical connecting rod is hollow inside, and is equipped with a ceramic piezoelectric sheet, which generates a piezoelectric effect after passing an electric current, and is used to transmit ultrasonic vibration; the waveguide sleeve is used to transmit and guide the focusing of ultrasonic waves on the metal wire;

[0012] The electromagnetic induction heating device comprises a high-frequency heating power supply, an induction coil, a T-type thermocouple element, and a digital thermometer; the high-frequency heating power supply is placed outside the induction coil and is used to output a high-frequency alternating current; the induction coil is installed outside the high-temperature wire feeding tube; the T-type thermocouple element is installed inside the high-temperature wire feeding tube and is used to detect the temperature of the metal wire; the digital thermometer is placed outside the thermocouple temperature measuring device and is connected to the T-type thermocouple through a wire to detect the temperature of the metal wire in real time;

[0013] The three-axis moving device includes a base, an XY moving platform, a Z-axis moving guide rail, a servo motor, a horizontal mounting frame, an XY plane moving guide rail, a Z-axis vertical mounting frame, and a substrate; the base is used to provide support and stability for the entire device and is fixed to the bottom of the device; the XY moving platform is installed on the upper part of the base to carry the workpiece moving in the XY plane; the Z-axis moving guide rail is installed on the Z-axis vertical mounting frame to guide the movement of the workpiece along the Z axis; the servo motor is installed outside the device to provide power for three-axis movement and real-time feedback of movement parameters; the transmission mechanism is connected to the XY moving platform and the Z-axis moving guide rail, and is mainly used to convert the rotational motion of the motor into linear motion; the substrate is used to carry the deposition piece and conduct heat to the deposition piece;

[0014] The preheating substrate device comprises a heating power supply, a heating plate, and a temperature sensor; the heating power supply is installed outside to provide the energy required for heating; the heating plate is installed at the bottom of the substrate for heating and conducting heat; the temperature sensor is installed at the edge of the substrate to detect the temperature of the substrate in real time;

[0015] The shear strain transmission device comprises a shear strain driving rod, a sliding joint, a shear strain deposition head, and a Z-axis movable guide rail; the shear strain driving rod is installed on the Z-axis movable guide rail for transmitting the force and movement of the shear strain; the sliding joint is installed between the shear strain deposition head and the wire feeding tube for relative displacement between the wire feeding tube and the shear strain transmission device; the shear strain deposition head is located at the lower end of the wire feeding tube mouth, contacts with the sample, and directly provides compressive stress;

[0016] The control system can simultaneously control the wire feeding system, the induction heating device, the preheating substrate device, and the ultrasonic auxiliary resonance device, and adjust the wire feeding speed, induction heating temperature, substrate preheating temperature, and ultrasonic frequency parameters of metal wire deposition in real time;

[0017] When the device is working, firstly, the substrate preheating temperature and the electromagnetic induction heating temperature are determined according to the melting point of the processed metal wire, and the appropriate wire feeding speed, shear strain transfer speed, and ultrasonic vibration frequency are adjusted to make the metal wire reach a softened state and complete the wire deposition; in the additive process, the electromagnetic induction heating device heats the metal wire by generating an induced current, so that the high-melting-point metal wire reaches a softened state, promoting and assisting the solid-state deposition of the metal wire; applying ultrasonic vibration to provide energy for the metal wire and generate a large number of dislocations, and high-frequency ultrasonic vibration can reduce the rheological stress of the metal material and accelerate the diffusion of atoms in the dislocations, thereby promoting the metallurgical bonding of adjacent metal units.

[0017] The shear strain transmission device comprises a shear strain driving rod, a sliding joint, a shear strain deposition head, and a Z-axis movable guide rail; the shear strain driving rod is installed on the Z-axis movable guide rail for transmitting the force and movement of the shear strain; the sliding joint is installed between the shear strain deposition head and the wire feeding tube for relative displacement between the wire feeding tube and the shear strain transmission device; the shear strain deposition head is located at the lower end of the wire feeding tube mouth, contacts with the sample, and directly provides compressive stress.

[0017] The electromagnetic induction heating device includes a high-frequency heating power supply, an induction coil, a T-type thermocouple element, and a digital thermometer; the high-frequency heating power supply is placed outside the induction coil and is used to output a high-frequency alternating current; the induction coil is installed outside the high-temperature wire feeding tube; the T-type thermocouple element is installed inside the high-temperature wire feeding tube and is used to detect the temperature of the metal wire; the digital thermometer is placed outside the thermocouple temperature measuring device and is connected to the T-type thermocouple through a wire to detect the temperature of the metal wire in real time.

[0018] An additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires, characterized by comprising the following steps:

[0019] Step 1: Cut the CAD model into multiple layers, generate a printing trajectory based on the shape of each layer, and determine the deposition route of the shear strain device;

[0020] Step 2: Calculate and determine the induction heating temperature and substrate preheating temperature according to the melting point of the deposited metal wire;

[0021] Step 3: For each layer of printing, according to the generated printing trajectory, the XY moving platform first moves the printing initial point to the specified location on the XY plane;

[0022] Step 4: The solid metal wire moves downward at a certain speed through the wire feeding system and passes through a hollow cylindrical shear strain transfer device with a diameter of 1 mm; the shear strain transfer device is connected to the ultrasonic resonance system, the ultrasonic generator in the ultrasonic resonance system converts electrical energy into vibration form and generates ultrasonic waves, the ultrasonic transducer absorbs the ultrasonic waves and converts them into vibration energy, and the ultrasonic vibration is transmitted to the metal wire wrapped in the wire feeding tube through the cylindrical connecting rod, and reciprocates along the axial direction of the cylindrical connecting rod;

[0023] Step 5: When the metal wire passes through the lower end of the wire feeding tube, it is assisted by the electromagnetic induction heating device. A high-temperature thermocouple is installed on the upper part of the electromagnetic induction heating device. The thermocouple can detect the temperature of the metal wire and feed it back to the control system. The real-time temperature of the electromagnetic induction heating device is adjusted by the control system to soften the metal wire and assist the deposition process of the metal wire.

[0024] Step 6: When the metal wire moves downward at a certain wire feeding speed after being assisted by ultrasonic resonance and electromagnetic induction heating, compressive stress is deposited through the shear strain transmission device. The shear strain transmission device moves up and down in the Z-axis direction through the Z-axis moving guide rail, and transmits power to the shear strain deposition head through the shear strain driving rod. The shear strain deposition head then applies stress to the metal wire that has been heated by electromagnetic induction and softened by ultrasonic resonance, thereby realizing the connection between any unit of the metal wire and the adjacent and lower layers.

[0025] Step 7: After one unit is deposited, the shear strain transfer device is lifted in the Z axis according to the diameter of the metal wire and moves a certain step length along the XY plane to deposit the next unit; the unit after deposition changes from the original circular cross section to a rectangular cross section;

[0026] Step 8: When switching to a new layer printing or printing direction reversal, the control system issues a command to suspend the conveying of the metal wire and the transmission of the shear strain deposition device; the Z-direction movement of the shear strain deposition head is completed by moving the Z-axis guide rail;

[0027] Step 9: Determine the wire feeding speed and shear strain transfer speed based on experimental experience. Perform substrate preheating, ultrasonic vibration, and electromagnetic induction heating assistance while feeding the metal wire. Repeat the above steps after completing one unit deposition until solid-state connection of the workpiece is achieved.

[0028] The present invention has the following beneficial effects:

[0029] The present invention adopts electromagnetic induction heating and ultrasonic resonance technology, which has a better softening effect on metal wires than ultrasonic resonance assisted deposition, and can realize the deposition of high-melting-point metal materials, such as titanium alloys, high-temperature alloys, and high-strength steels; the present invention completes wire deposition by softening the metal wire and applying mechanical stress, which belongs to "cold forming". Compared with laser or electron beam additive manufacturing, it reduces phase change stages such as melting and cooling, and reduces the generation of thermal cracks in the deposited workpiece; in the deposition process, there is ultrasonic assisted vibration, which provides energy for the metal wire and generates a large number of dislocations. High-frequency ultrasonic vibration can reduce the rheological stress of the metal material and accelerate the diffusion of atoms in the dislocations, thereby promoting the metallurgical bonding of adjacent metal units. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A schematic side view of an additive device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire;

[0031] Figure 2 A schematic diagram of a front view of an additive device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire;

[0032] Figure 3 A schematic diagram of an induction heating device in an additive device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire;

[0033] Figure 4 A schematic diagram of an ultrasonic resonance system in an additive device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire;

[0034] Figure 5 A schematic diagram of a shear strain transfer device in an additive device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire;

[0035] Figure 6 A schematic diagram of the surface texture during the printing process of an additive device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire;

[0036] in,

[0037] 1-wire feeding system; 2-control system; 3-ultrasonic resonance system; 4-electromagnetic induction heating device; 5-three-axis moving device; 6-preheating substrate device; 7-shear strain transfer device; 8-straightening device; 9-metal wire; 10-high temperature wire feeding tube; 11-ultrasonic generator assembly plate; 12-transverse connecting rod;

[0038] 100-wire feeding disc; 101-driving part; 102-pressure wheel; 103-adjustable preload pressure rod; 104-driving wheel; 105-driven wheel; 106-wire feeding motor;

[0039] 200-Computer systems;

[0040] 300-ultrasonic generator; 301-ultrasonic transducer; 302-cylindrical connecting rod; 303-ceramic piezoelectric sheet; 304-waveguide sleeve;

[0041] 400-high frequency heating power supply; 401-induction coil; 402-temperature measuring thermocouple; 403-digital thermometer;

[0042] 500-base; 501-XY moving platform; 502-Z axis moving guide rail; 503-servo motor; 504-Z axis horizontal mounting frame; 505-XY plane moving guide rail; 506-Z axis vertical mounting frame; 507-base plate;

[0043] 600-heating power supply; 601-heating plate; 602-temperature sensor;

[0044] 700 - shear strain driving rod; 701 - sliding joint; 702 - shear strain deposition head; 703 - Z-axis moving guide rail. DETAILED DESCRIPTION

[0045] In order to make the technical problems solved by the present invention, the technical solutions adopted and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0046] In the description of this embodiment, terms such as "up", "down", "left", and "right" and other orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation.

[0047] The technical solution of the present invention is further described below with reference to the accompanying drawings and through specific implementation methods.

[0048] refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 As shown, an additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires are characterized by: comprising a wire feeding system 1, a control system 2, an ultrasonic resonance device 3, an electromagnetic induction heating device 4, a three-axis moving system 5, a preheating substrate device 6, and a shear strain transfer device 7;

[0049] The wire feeding system includes a wire feeding motor 106 and a wire feeding drive device 101; the wire feeding motor 106 is placed on one side of the wire feeding drive device 101 to provide power, the pre-tightening rod 103 on one side of the wire feeding drive device 101 acts on the clamping wheel 102 to clamp the metal wire 9, the driving wheel 104 is driven by the motor 106 to drive the driven wheel 105 to rotate, and then the metal wire 9 is driven downward by friction; the welding wire drive device is connected to the Z-axis vertical mounting frame 506 through two transverse connecting rods 12;

[0050] The ultrasonic resonance system includes an ultrasonic generator 300, an ultrasonic transducer 301, a cylindrical connecting rod 302, a ceramic piezoelectric sheet 303, and a waveguide sleeve 304; the ultrasonic generator 300 is mounted on a Z-axis vertical mounting frame 506, and is used to convert electrical energy into a high-frequency alternating current signal that matches the ultrasonic transducer; the ultrasonic transducer 301 is fixed on the cylindrical connecting rod 302 and is connected to the ultrasonic generator 300 through a wire; the right side of the cylindrical connecting rod 302 is connected to the Z-axis horizontal mounting frame 504, the cylindrical connecting rod 302 is hollow inside, and is equipped with a ceramic piezoelectric sheet 303, which generates a piezoelectric effect after passing an electric current, and is used to transmit ultrasonic vibration; the waveguide sleeve 304 is used to transmit and guide the focusing of ultrasonic waves on the metal wire 9;

[0051] The electromagnetic induction heating device comprises a high-frequency heating power supply 400, an induction coil 401, a T-type thermocouple element 402, and a digital thermometer 403; the high-frequency heating power supply 400 is placed outside the induction coil 401, and is used to output a high-frequency alternating current; the induction coil 401 is installed outside a high-temperature resistant pipeline for conveying metal wires; the T-type thermocouple element 402 is placed inside the wire-feeding high-temperature pipeline, and is used to detect the temperature of the metal wires and form a contact point; the digital thermometer 403 is placed outside the thermocouple temperature measuring device, and is connected to the T-type thermocouple 402 through a wire, and detects the temperature of the metal wires in real time;

[0052] The three-axis moving device includes a base 500, an XY moving platform 501, a Z-axis moving guide rail 502, a servo motor 503, a Z horizontal mounting frame 504, an XY plane moving guide rail 505, a Z-axis vertical mounting frame 506, and a base plate 507; the base 500 is used to provide support and stability for the entire device and is fixed at the bottom of the device; the XY moving platform 501 is installed on the upper part of the base to carry the workpiece moving in the XY plane; the Z-axis moving guide rail 502 is installed on the Z-axis vertical mounting frame 506 to guide the movement of the workpiece along the Z axis; the servo motor 503 is installed outside the device to provide power for three-axis movement and real-time feedback of movement parameters; the transmission mechanism is connected to the XY moving platform 501 and the Z-axis moving guide rail 502, and is mainly used to convert the rotational motion of the motor into linear motion; the base plate 507 is used to carry the deposition piece and conduct heat;

[0053] The preheating substrate device includes a heating source 600, a heating plate 601, and a temperature sensor 602; the heating source 600 is installed at the lower side of the XY moving platform 501 for heating the substrate; the temperature sensor 602 is installed inside the substrate 507 to detect the temperature of the substrate 507 in real time;

[0054] The shear strain transmission device includes a shear strain driving rod 700, a sliding joint 701, a shear strain deposition head 702, and a Z-axis movable guide rail 703; the shear strain driving rod 700 is installed on the Z-axis movable guide rail 703, and is used to transmit the force and movement of the shear strain; the sliding joint 701 is installed between the shear strain deposition head 702 and the wire feeding tube 10, and is used for the relative displacement between the wire feeding tube 10 and the shear strain deposition head 702; the shear strain deposition head 702 is located at the lower end of the wire feeding tube mouth, contacts with the sample, and directly provides compressive stress;

[0055] The control system 2 can simultaneously control the wire feeding system 1, the induction heating system 4, the preheating substrate device 6, and the ultrasonic auxiliary resonance system 3, and adjust the wire feeding speed, induction heating temperature, substrate preheating temperature, and ultrasonic frequency parameters during the deposition of the metal wire 9 in real time;

[0056] When the device is working, firstly, the substrate preheating temperature and the electromagnetic induction heating temperature are determined according to the melting point of the processed metal wire, and the appropriate wire feeding speed, shear strain transfer speed, and ultrasonic vibration frequency are adjusted to make the metal wire reach a softened state and complete the wire deposition; in the additive process, the electromagnetic induction heating device heats the metal wire by generating an induced current, so that the high-melting-point metal wire reaches a softened state, promoting and assisting the solid-state deposition of the metal wire; applying ultrasonic vibration to provide energy for the metal wire and generate a large number of dislocations, and high-frequency ultrasonic vibration can reduce the rheological stress of the metal material and accelerate the diffusion of atoms in the dislocations, thereby promoting the metallurgical bonding of adjacent metal units.

[0056] The shear strain transmission device includes a shear strain driving rod 700, a sliding joint 701, a shear strain deposition head 702, and a Z-axis moving guide rail 703; one side of the lower end of the shear strain deposition head is an acute-angle cross-section, and the other side is a semi-rectangular cross-section, the purpose of which is to guide the deposition direction of the metal wire;

[0056] The induction heating system 4 includes: a high-frequency heating power supply 400, an induction coil 401, a T-type thermocouple element 402, and a digital thermometer 403; the high-frequency heating power supply 400 is used to generate alternating current; the induction coil 401 is used to generate an alternating magnetic field through an alternating current; the digital thermometer 403 is placed outside the thermocouple temperature measuring device, connected to the T-type thermocouple 402 through a wire, and detects the temperature of the metal wire 9 in real time;

[0057] An additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires, characterized by comprising the following steps:

[0058] Step 1: Cut the CAD model into multiple layers, generate a printing trajectory based on the shape of each layer, and determine the deposition route of the shear strain device;

[0059] Step 2: Calculate and determine the induction heating temperature and substrate preheating temperature according to the melting point of the deposited metal wire;

[0060] Step 3: For each layer of printing, according to the generated printing trajectory, the XY moving platform first moves the printing initial point to the specified location on the XY plane;

[0061] Step 4: The solid metal wire moves downward at a certain speed through the wire feeding system and passes through a hollow cylindrical shear strain transfer device with a diameter of 1 mm; the shear strain transfer device is connected to the ultrasonic resonance system, the ultrasonic generator in the ultrasonic resonance system converts electrical energy into vibration form and generates ultrasonic waves, the ultrasonic transducer absorbs the ultrasonic waves and converts them into vibration energy, and the ultrasonic vibration is transmitted to the metal wire wrapped in the wire feeding tube through the cylindrical connecting rod, and reciprocates along the axial direction of the cylindrical connecting rod;

[0062] Step 5: When the metal wire passes through the lower end of the wire feeding tube, it is assisted by the electromagnetic induction heating device. A high-temperature thermocouple is installed on the upper part of the electromagnetic induction heating device. The thermocouple can detect the temperature of the metal wire and feed it back to the control system. The real-time temperature of the electromagnetic induction heating device is adjusted by the control system to soften the metal wire and assist the deposition process of the metal wire.

[0063] Step 6: When the metal wire moves downward at a certain wire feeding speed after being assisted by ultrasonic resonance and electromagnetic induction heating, compressive stress is deposited through the shear strain transmission device. The shear strain transmission device moves up and down in the Z-axis direction through the Z-axis moving guide rail, and transmits power to the shear strain deposition head through the shear strain driving rod. The shear strain deposition head then applies stress to the metal wire that has been heated by electromagnetic induction and softened by ultrasonic resonance, thereby realizing the connection between any unit of the metal wire and the adjacent and lower layers.

[0064] Step 7: After one unit is deposited, the shear strain transfer device is lifted in the Z axis according to the diameter of the metal wire and moves a certain step length along the XY plane to deposit the next unit; the unit after deposition changes from the original circular cross section to a rectangular cross section;

[0065] Step 8: When switching to a new layer printing or printing direction reversal, the control system issues a command to suspend the conveying of the metal wire and the transmission of the shear strain deposition device; the Z-direction movement of the shear strain deposition head is completed by moving the Z-axis guide rail;

[0066] Step 9: Determine the wire feeding speed and shear strain transfer speed based on experimental experience. Perform substrate preheating, ultrasonic vibration, and electromagnetic induction heating assistance while feeding the metal wire. Repeat the above steps after completing one unit deposition until solid-state connection of the workpiece is achieved.

[0067] The present invention is further described below by a specific embodiment.

[0068] The TC4 quadrilateral square tube thin-walled parts were prepared using the above device.

[0069] The substrate used is a 40mm*40mm*8mm H13 tool steel plate, and the composition of the titanium alloy wire is 90% Cu, 5.5% Al, 3.5% V, 0.25% Fe, 0.2% O, 0.05% N, 0.015% H, and 0.035% other impurities.

[0070] Firstly, the quadrilateral thin-walled square tube CAD model is cut into multiple layers, each layer is a 4×4 mm square. According to the melting point of the titanium alloy wire of 1650°C, the induction heating temperature and substrate preheating temperature are determined to be 1200°C and 200°C respectively.

[0071] Furthermore, according to the generated printing trajectory, the initial printing point of the XY mobile platform is moved to (2, 2, 0) in the XY plane; the diameter of the solid metal wire is 0.5 mm, the wire feeding speed is 2 mm / s, and the titanium alloy wire passes through a hollow cylindrical shear strain transfer device with a diameter of 1 mm; the frequency of ultrasonic vibration is 40 kHz and the amplitude is 10 μm; the period of printing one unit by the shear strain transfer device is 0.025 s, and the oscillating shear displacement is 1×10 -4 m.

[0072] Furthermore, each system is started, and ultrasonic resonance-assisted deposition of the unit is performed according to the generated printing trajectory and parameters. After one unit deposition is completed, the shear strain transfer device is lifted by 0.25 mm in the X-axis and moved by 1 mm along the XY plane to deposit the next unit; the thickness of a single layer is 0.2 mm. When printing the next layer, the shear strain deposition head moves upward by 0.2 mm through the Z-axis moving guide rail, and the new layer repeats the above process according to the predetermined trajectory until the additive manufacturing of the quadrilateral square tube thin-walled parts is completed.

[0073] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. An additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wire, characterized in that: It includes a wire feeding system, a control system, an ultrasonic resonance system, an electromagnetic induction heating device, a three-axis moving device, a substrate preheating device, and a shear strain transfer device; The wire feeding system includes a wire feeding motor and a driving device; the wire feeding motor is placed outside the driving device to provide power, a pre-tightening rod on one side of the wire feeding driving device acts on the clamping wheel to clamp the metal wire, the motor drives the driving wheel to drive the driven wheel to rotate, and the metal wire is driven downward by friction; the driving device is connected to the Z-axis vertical mounting frame through two transverse connecting rods; The ultrasonic resonance system comprises an ultrasonic generator, an ultrasonic transducer, a cylindrical connecting rod, and a ceramic piezoelectric sheet; the ultrasonic generator is mounted on a Z-axis transverse mounting frame and is used to convert electrical energy into a high-frequency alternating current signal that matches the ultrasonic transducer; the ultrasonic transducer is fixed on the cylindrical connecting rod and is connected to the ultrasonic generator through a wire; the right side of the cylindrical connecting rod is connected to the Z-axis transverse mounting frame, the cylindrical connecting rod is hollow inside, and is equipped with a ceramic piezoelectric sheet, which generates a piezoelectric effect after passing an electric current, and is used to transmit ultrasonic vibration; the waveguide sleeve is used to transmit and guide the focusing of ultrasonic waves on the metal wire; The electromagnetic induction heating device comprises a high-frequency heating power supply, an induction coil, a T-type thermocouple element, and a digital thermometer; the high-frequency heating power supply is placed outside the induction coil and is used to output a high-frequency alternating current; the induction coil is installed outside the high-temperature wire feeding tube; the T-type thermocouple element is installed inside the high-temperature wire feeding tube and is used to detect the temperature of the metal wire; the digital thermometer is placed outside the thermocouple temperature measuring device and is connected to the T-type thermocouple through a wire to detect the temperature of the metal wire in real time; The three-axis moving device includes a base, an XY moving platform, a Z-axis moving guide rail, a servo motor, a horizontal mounting frame, an XY plane moving guide rail, a Z-axis vertical mounting frame, and a substrate; the base provides support and stability for the entire device and is fixed to the bottom of the device; the XY moving platform is installed on the upper part of the base to carry the workpiece moving in the XY plane; the Z-axis moving guide rail is installed on the Z-axis vertical mounting frame to guide the movement of the workpiece along the Z axis; the servo motor is installed outside the device to provide power for three-axis movement and provide real-time feedback of movement parameters; the transmission mechanism is connected to the XY moving platform and the Z-axis moving guide rail, and is mainly used to convert the rotational motion of the motor into linear motion; the substrate is used to carry the deposition piece and conduct heat to the deposition piece; The preheating substrate device comprises a heating power supply, a heating plate, and a temperature sensor; the heating power supply is installed outside the substrate device to provide the energy required for heating; the heating plate is installed under the substrate for heating and conducting heat; the temperature sensor is installed at the edge of the substrate to detect the temperature of the substrate in real time; The shear strain transmission device comprises a shear strain driving rod, a sliding joint, a shear strain deposition head, and a Z-axis movable guide rail; the shear strain driving rod is installed on the Z-axis movable guide rail for transmitting the force and movement of the shear strain; the sliding joint is installed between the shear strain deposition head and the wire feeding tube for relative displacement between the wire feeding tube and the shear strain transmission device; the shear strain deposition head is located at the lower end of the wire feeding tube mouth, contacts with the sample, and directly provides compressive stress; The control system can simultaneously control the wire feeding system, the induction heating device, the preheating substrate device, and the ultrasonic resonance system, and adjust the wire feeding speed, the induction heating temperature, the substrate preheating temperature, the ultrasonic frequency parameters, and the working frequency of the shear strain transfer device for metal wire deposition in real time; When the device is working, firstly, the substrate preheating temperature and the electromagnetic induction heating temperature are determined according to the melting point of the processed metal wire, and the appropriate wire feeding speed, shear strain transfer speed, and ultrasonic vibration frequency are adjusted to make the metal wire reach a softened state and complete the wire deposition; in the additive process, the electromagnetic induction heating device heats the metal wire by generating an induced current, so that the high-melting-point metal wire reaches a softened state, promoting and assisting the solid-state deposition of the metal wire; applying ultrasonic vibration to provide energy for the metal wire and generate a large number of dislocations, and high-frequency ultrasonic vibration can reduce the rheological stress of the metal material and accelerate the diffusion of atoms in the dislocations, thereby promoting the metallurgical bonding of adjacent metal units.

2. The device for adding materials by ultrasonic resonance-assisted direct deposition of high-melting-point metal materials according to claim 1, characterized in that: The shear strain transmission device comprises a shear strain driving rod, a sliding joint, a shear strain deposition head, and a Z-axis movable guide rail; the shear strain driving rod is installed on the Z-axis movable guide rail for transmitting the force and movement of the shear strain; the sliding joint is installed between the shear strain deposition head and the wire feeding tube for relative displacement between the wire feeding tube and the shear strain transmission device; the shear strain deposition head is located at the lower end of the wire feeding tube mouth, contacts with the sample, and directly provides compressive stress.

3. The device for adding materials by ultrasonic resonance-assisted direct deposition of high-melting-point metal materials according to claim 1, characterized in that: The electromagnetic induction heating device includes a high-frequency heating power supply, an induction coil, a T-type thermocouple element, and a digital thermometer; the high-frequency heating power supply is placed outside the induction coil and is used to output a high-frequency alternating current; the induction coil is installed outside the high-temperature wire feeding tube; the T-type thermocouple element is installed inside the high-temperature wire feeding tube and is used to detect the temperature of the metal wire; the digital thermometer is placed outside the thermocouple temperature measuring device and is connected to the T-type thermocouple through a wire to detect the temperature of the metal wire in real time.

4. An additive device and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires, Its characteristics include the following steps: Step 1: Cut the CAD model into multiple layers, generate a printing trajectory based on the shape of each layer, and determine the deposition route of the shear strain device; Step 2: Calculate and determine the induction heating temperature and substrate preheating temperature according to the melting point of the deposited metal wire; Step 3: For each layer of printing, according to the generated printing trajectory, the XY moving platform first moves the printing initial point to the specified location on the XY plane; Step 4: The solid metal wire moves downward at a certain speed through the wire feeding system and passes through a hollow cylindrical shear strain transfer device with a diameter of 1 mm; the shear strain transfer device is connected to the ultrasonic resonance system, the ultrasonic generator in the ultrasonic resonance system converts electrical energy into vibration form and generates ultrasonic waves, the ultrasonic transducer absorbs the ultrasonic waves and converts them into vibration energy, and the ultrasonic vibration is transmitted to the metal wire wrapped in the wire feeding tube through the cylindrical connecting rod, and reciprocates along the axial direction of the cylindrical connecting rod; Step 5: When the metal wire passes through the lower end of the wire feeding tube, it is assisted by the electromagnetic induction heating device. A high-temperature thermocouple is installed on the upper part of the electromagnetic induction heating device. The thermocouple can detect the temperature of the metal wire and feed it back to the control system. The real-time temperature of the electromagnetic induction heating device is adjusted by the control system to soften the metal wire and assist the deposition process of the metal wire. Step 6: When the metal wire moves downward at a certain wire feeding speed after being assisted by ultrasonic resonance and electromagnetic induction heating, compressive stress is deposited through the shear strain transmission device. The shear strain transmission device moves up and down in the Z-axis direction through the Z-axis moving guide rail, and transmits power to the shear strain deposition head through the shear strain driving rod. The shear strain deposition head then applies stress to the metal wire that has been heated by electromagnetic induction and softened by ultrasonic resonance, thereby realizing the connection between any unit of the metal wire and the adjacent and lower layers. Step 7: After one unit is deposited, the shear strain transfer device is lifted in the Z axis according to the diameter of the metal wire and moves a certain step length along the XY plane to deposit the next unit; the unit after deposition changes from the original circular cross section to a rectangular cross section; Step 8: When switching to a new layer printing or printing direction reversal, the control system issues a command to suspend the conveying of the metal wire and the transmission of the shear strain deposition device; the Z-direction movement of the shear strain deposition head is completed by moving the Z-axis guide rail; Step 9: Determine the wire feeding speed and shear strain transfer speed based on experimental experience. Perform substrate preheating, ultrasonic vibration, and electromagnetic induction heating assistance while feeding the metal wire. Repeat the above steps after completing one unit deposition until solid-state connection of the workpiece is achieved.

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