A high melting point metal wire material ultrasonic resonance assisted direct deposition additive device and method

Abstract

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

Description

Technical Field

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

[0002] Additive manufacturing is a method of material forming and joining, in which the forming and joining of materials occur simultaneously or sequentially. The forming and joining of materials essentially begin with defects such as dislocations sliding along slip surfaces in metals, while joining involves the exchange of mass across boundaries or interfaces between adjacent domains of the metal. Mass transfer processes such as diffusion or advection mixing drive the fusion of interfaces in the joining process. Both forming and joining require energy input to overcome initial energy barriers and maintain the continuity of these processes. In addition to the energy input used to drive these processes, additional energy can be used to assist them, allowing for greater deformation or accelerating diffusion behavior.

[0003] Currently available metal additive manufacturing processes include laser or electron beam additive manufacturing, polymer binder deposition, ultrasonic additive manufacturing, and friction stir welding additive manufacturing. Laser and electron beam additive manufacturing melts metal powder or wire along a predetermined path to form a molten pool with the base material, which then solidifies, forming a solid object row by row and layer by layer. Polymer binder deposition is a technique that uses a binder to sinter metal particles together. Ultrasonic additive manufacturing and friction stir welding additive manufacturing use localized frictional melting and mechanical strain to shape raw materials and join them into a solid.

[0004] Ultrasonic resonance-assisted deposition (URAD) combines ultrasonic vibration with additive manufacturing. Metal wires are softened by ultrasonic vibration and then deformed by extrusion to bond tightly to the substrate and the deposited layer. Compared to powder bed fusion and directional energy deposition, URAD eliminates the need to melt the metal wires or powders. Instead, it utilizes ultrasonic vibration to induce softening and solid-state bonding of the metal wires, achieving "cold" forming. Compared to ultrasonic friction stir welding and ultrasonic powder deposition, URAD offers higher vibration frequencies and smaller amplitudes, enabling more precise energy input and plastic flow control. Ultrasonic vibration also has a strain-promoting effect, accelerating atomic diffusion and achieving metallurgical bonding of the metal wires in a cold state.

[0005] Ultrasonic resonance-assisted deposition is a novel additive manufacturing technology that has already achieved good printing results on 6061 and 7075 aluminum alloys. However, for high-melting-point metal materials such as titanium alloys, high-temperature alloys, and high-strength steel, the heat generated by ultrasonic vibration alone is insufficient to soften these materials and achieve metallurgical bonding.

[0006] Electromagnetic induction heating is a heating method that converts electrical energy into heat energy using the principle of electromagnetic induction. Its basic principle is to generate eddy currents inside a conductor through high-frequency current, thereby causing the conductor to heat up. Compared with traditional heating methods, electromagnetic induction heating has advantages such as fast heating speed, high efficiency, precise temperature control, and uniform heating. Summary of the Invention

[0007] The purpose of this invention is to address the limitation that ultrasonic resonance-assisted deposition alone is insufficient to soften high-melting-point metal wires. This invention provides an additive manufacturing apparatus and method for direct deposition of high-melting-point metal wires using ultrasonic resonance assistance. By installing an electromagnetic induction heating device at a certain distance above the wire feed outlet, the metal wire is softened. Ultrasonic resonance further aids in the breaking and homogenization of the metal wire, compressing it to deform it and tightly bonding it to the substrate and the deposited layer, thereby achieving additive manufacturing of high-melting-point metal wires.

[0008] The technical solution is as follows:

[0009] The additive manufacturing apparatus and method for 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 triaxial moving device, a preheating substrate device, and a shear strain transfer device.

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

[0011] The ultrasonic resonance system includes an ultrasonic generator, an ultrasonic transducer, a cylindrical connecting rod, and a ceramic piezoelectric element. The ultrasonic generator is mounted on a Z-axis transverse mounting bracket and is used to convert electrical energy into a high-frequency AC signal that matches the ultrasonic transducer. The ultrasonic transducer is fixed to the cylindrical connecting rod and connected to the ultrasonic generator via a wire. The right side of the cylindrical connecting rod is connected to the Z-axis transverse mounting bracket. The cylindrical connecting rod is hollow inside and contains a ceramic piezoelectric element. The piezoelectric element generates a piezoelectric effect after current passes through it, which is used to transmit ultrasonic vibrations. The waveguide sleeve is used to transmit and guide the focusing of ultrasonic waves on a metal wire.

[0012] 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.

[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 base plate. The base provides support and stability for the entire device and is fixed to the bottom of the device. The XY moving platform is mounted on the upper part of the base and is used to support the workpiece moving in the XY plane. The Z-axis moving guide rail is mounted on the Z-axis vertical mounting frame and is used to guide the movement of the workpiece along the Z-axis. The servo motor is mounted outside the device and is used to provide power for the three-axis movement and provide real-time feedback of motion 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 base plate is used to support the deposited part and conduct heat to the deposited part.

[0014] The preheating substrate device includes a heating power supply, a heating plate, and a temperature sensor; the heating power supply is mounted on the outside to provide the energy required for heating; the heating plate is mounted on the lower part of the substrate for heating and conducting heat; the temperature sensor is mounted on the edge of the substrate to detect the temperature of the substrate in real time.

[0015] The shear strain transfer device includes a shear strain drive rod, a sliding joint, a shear strain deposition head, and a Z-axis moving guide rail. The shear strain drive rod is mounted on the Z-axis moving guide rail and is used to transfer the force and motion of shear strain. The sliding joint is installed between the shear strain deposition head and the wire feeding tube and is used for the relative displacement between the wire feeding tube and the shear strain transfer device. The shear strain deposition head is located at the lower end of the wire feeding tube and is in contact with the sample, directly providing compressive stress.

[0016] The control system can simultaneously control the wire feeding system, induction heating device, substrate preheating device, and ultrasonic-assisted 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 in operation, the substrate preheating temperature and electromagnetic induction heating temperature are first determined according to the melting point of the metal wire being processed. The appropriate wire feeding speed, shear strain transmission speed, and ultrasonic vibration frequency are adjusted to soften the metal wire and complete the wire deposition. During the additive manufacturing process, the electromagnetic induction heating device heats the metal wire by generating an induced current, softening the high-melting-point metal wire and promoting and assisting the solid-state deposition of the metal wire. Ultrasonic vibration is applied to provide energy to the metal wire and generate 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, promoting the metallurgical bonding of adjacent metal units.

[0018] The shear strain transfer device includes a shear strain drive rod, a sliding joint, a shear strain deposition head, and a Z-axis moving guide rail. The shear strain drive rod is mounted on the Z-axis moving guide rail and is used to transfer the force and motion of shear strain. The sliding joint is installed between the shear strain deposition head and the wire feeding tube and is used for the relative displacement between the wire feeding tube and the shear strain transfer device. The shear strain deposition head is located at the lower end of the wire feeding tube and is in contact with the sample, directly providing compressive stress.

[0019] 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.

[0020] An additive manufacturing apparatus and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires, characterized by the following steps:

[0021] Step 1: Cut the CAD model into multiple layers, generate printing trajectories based on the shape of each layer, and determine the deposition path of the shear strain device;

[0022] Step 2: Calculate and determine the induction heating temperature and substrate preheating temperature based on the melting point of the metal wire to be deposited;

[0023] Step 3: For printing each layer, based on the generated printing trajectory, the XY moving platform first moves the initial printing point to the specified location on the XY plane;

[0024] 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 and generates ultrasonic waves. The ultrasonic transducer absorbs the ultrasonic waves and converts them into vibration energy. The ultrasonic vibration is transmitted to the metal wire wrapped in the wire feeding tube through the cylindrical connecting rod and vibrates back and forth along the axial direction of the cylindrical connecting rod.

[0025] Step 5: When the metal wire passes through the bottom of the wire feeding tube, it is heated by an 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 control system adjusts the real-time temperature of the electromagnetic induction heating device to soften the metal wire and assist the deposition process of the metal wire.

[0026] Step 6: When the metal wire moves downward at a certain feeding speed after ultrasonic resonance assistance and electromagnetic induction heating, it undergoes compressive stress deposition through a shear strain transfer device. The shear strain transfer 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 drive rod. The shear strain deposition head then applies stress to the metal wire that has been softened by electromagnetic induction heating and ultrasonic resonance, thereby realizing the connection between any unit of the metal wire and the adjacent and lower layers.

[0027] Step 7: After one unit deposition is completed, the shear strain transfer device is lifted along 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 deposited unit changes from the original circular cross section to a rectangular cross section.

[0028] Step 8: When switching to a new layer for printing or changing the printing direction, the control system issues a command to pause the feeding of the metal wire and the transmission of the shear strain deposition device; the shear strain deposition head moves in the Z direction via the Z-axis moving guide rail.

[0029] Step 9: Determine the wire feeding speed and shear strain transfer speed based on experimental experience. Simultaneously perform substrate preheating, ultrasonic vibration, and electromagnetic induction heating assistance while the metal wire is being fed in. Repeat the above steps after completing the deposition of one unit until solid-state connection of the workpiece is achieved.

[0030] The present invention has the following beneficial effects:

[0031] This invention employs electromagnetic induction heating and ultrasonic resonance technology, which offers better softening effects on metal wires compared to ultrasonic resonance-assisted deposition, enabling the deposition of high-melting-point metal materials such as titanium alloys, high-temperature alloys, and high-strength steel. This invention completes wire deposition by softening the metal wire and applying mechanical stress, a process known as "cold forming." Compared to laser or electron beam additive manufacturing, it reduces the melting and cooling phase transformation stages, thus minimizing the generation of thermal cracks in the deposited workpiece. During the deposition process, ultrasonic-assisted vibration provides energy to the metal wire and generates numerous dislocations. High-frequency ultrasonic vibration reduces the rheological stress of the metal material and accelerates atomic diffusion within the dislocations, promoting metallurgical bonding between adjacent metal units. Attached Figure Description

[0032] Figure 1 This is a side view of an additive manufacturing device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires.

[0033] Figure 2 A front view of an additive manufacturing device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires;

[0034] Figure 3 This is a schematic diagram of an induction heating device in an additive manufacturing apparatus for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires.

[0035] Figure 4 This is a schematic diagram of the ultrasonic resonance system in an additive manufacturing device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires.

[0036] Figure 5 This is a schematic diagram of a shear strain transfer device in an additive manufacturing apparatus for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires.

[0037] Figure 6 This is a schematic diagram of the surface texture during the printing process of an additive manufacturing device that uses ultrasonic resonance-assisted direct deposition of high-melting-point metal wires.

[0038] in,

[0039] 1-Wire feeding system; 2-Control system; 3-Ultrasonic resonance system; 4-Electromagnetic induction heating device; 5-Triaxial 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.

[0040] 100-Wire feeding spool; 101-Drive unit; 102-Pressure roller; 103-Adjustable preload pressure bar; 104-Drive wheel; 105-Driven wheel; 106-Wire feeding motor;

[0041] 200 - Computer Systems;

[0042] 300 - Ultrasonic generator; 301 - Ultrasonic transducer; 302 - Cylindrical connecting rod; 303 - Ceramic piezoelectric element; 304 - Waveguide bushing;

[0043] 400 - High-frequency heating power supply; 401 - Induction coil; 402 - Temperature measuring thermocouple; 403 - Digital thermometer;

[0044] 500 - Base; 501 - XY moving platform; 502 - Z-axis moving guide rail; 503 - Servo motor; 504 - Z-axis horizontal mounting bracket; 505 - XY planar moving guide rail; 506 - Z-axis vertical mounting bracket; 507 - Base plate;

[0045] 600 - Heating power supply; 601 - Heating plate; 602 - Temperature sensor;

[0046] 700 - Shear strain drive rod; 701 - Sliding joint; 702 - Shear strain deposition head; 703 - Z-axis moving guide rail. Detailed Implementation

[0047] 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 with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0048] In the description of this embodiment, the terms "upper", "lower", "left", "right", etc., are based on the orientation or positional relationship 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, or be constructed and operated in a specific orientation.

[0049] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0050] refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 , Figure 6 As shown, an additive manufacturing apparatus and method for direct deposition of high-melting-point metal wires by ultrasonic resonance assistance is characterized by comprising: a wire feeding system 1, a control system 2, an ultrasonic resonance device 3, an electromagnetic induction heating device 4, a triaxial movement system 5, a preheating substrate device 6, and a shear strain transfer device 7.

[0051] 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, thereby driving the metal wire 9 downward by friction. The welding wire drive device is connected to the Z-axis vertical mounting bracket 506 through two transverse connecting rods 12.

[0052] The ultrasonic resonance system includes an ultrasonic generator 300, an ultrasonic transducer 301, a cylindrical connecting rod 302, a ceramic piezoelectric element 303, and a waveguide sleeve 304. The ultrasonic generator 300 is mounted on a Z-axis vertical mounting bracket 506 and is used to convert electrical energy into a high-frequency AC signal that matches the ultrasonic transducer. The ultrasonic transducer 301 is fixed on the cylindrical connecting rod 302 and connected to the ultrasonic generator 300 via a wire. The right side of the cylindrical connecting rod 302 is connected to the Z-axis transverse mounting bracket 504. The cylindrical connecting rod 302 is hollow inside and has a ceramic piezoelectric element 303 installed inside. The piezoelectric element generates a piezoelectric effect after passing current through it, which is used to transmit ultrasonic vibrations. The waveguide sleeve 304 is used to transmit and guide the focusing of ultrasonic waves on the metal wire 9.

[0053] The electromagnetic induction heating device 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 placed outside the induction coil 401 and is used to output high-frequency alternating current. The induction coil 401 is installed outside the high-temperature resistant pipe for conveying the metal wire. The T-type thermocouple element 402 is placed inside the high-temperature pipe for feeding the wire and is used to detect the temperature of the metal wire and form a contact. The digital thermometer 403 is placed outside the thermocouple temperature measuring device and is connected to the T-type thermocouple 402 through a wire to detect the temperature of the metal wire in real time.

[0054] 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-axis horizontal mounting bracket 504, an XY plane moving guide rail 505, a Z-axis vertical mounting bracket 506, and a base plate 507. The base 500 provides support and stability for the entire device and is fixed to the bottom of the device. The XY moving platform 501 is mounted on the upper part of the base and carries the workpiece moving in the XY plane. The Z-axis moving guide rail 502 is mounted on the Z-axis vertical mounting bracket 506 and guides the workpiece along the Z-axis. The servo motor 503 is mounted outside the device and provides power for the three-axis movement and provides real-time feedback of motion 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 carries the deposited part and conducts heat.

[0055] The preheating substrate device includes a heating source 600, a heating plate 601, and a temperature sensor 602; the heating source 600 is installed on 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.

[0056] The shear strain transmission device includes a shear strain drive rod 700, a sliding joint 701, a shear strain deposition head 702, and a Z-axis moving guide rail 703. The shear strain drive rod 700 is mounted on the Z-axis moving guide rail 703 and is used to transmit the force and motion of 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 opening, in contact with the sample, and directly provides compressive stress.

[0057] 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-assisted 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.

[0058] When the device is in operation, the substrate preheating temperature and electromagnetic induction heating temperature are first determined according to the melting point of the metal wire being processed. The appropriate wire feeding speed, shear strain transmission speed, and ultrasonic vibration frequency are adjusted to soften the metal wire and complete the wire deposition. During the additive manufacturing process, the electromagnetic induction heating device heats the metal wire by generating an induced current, softening the high-melting-point metal wire and promoting and assisting the solid-state deposition of the metal wire. Ultrasonic vibration is applied to provide energy to the metal wire and generate 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, promoting the metallurgical bonding of adjacent metal units.

[0059] The shear strain transfer device includes a shear strain drive rod 700, a sliding joint 701, a shear strain deposition head 702, and a Z-axis moving guide rail 703; the lower end of the shear strain deposition head has an acute-angle cross-section on one side and a semi-rectangular cross-section on the other side, which is intended to guide the deposition direction of the metal wire.

[0060] 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 alternating current; the digital thermometer 403 is placed outside the thermocouple temperature measuring device and connected to the T-type thermocouple 402 through a wire to detect the temperature of the metal wire 9 in real time.

[0061] An additive manufacturing apparatus and method for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires, characterized by the following steps:

[0062] Step 1: Cut the CAD model into multiple layers, generate printing trajectories based on the shape of each layer, and determine the deposition path of the shear strain device;

[0063] Step 2: Calculate and determine the induction heating temperature and substrate preheating temperature based on the melting point of the metal wire to be deposited;

[0064] Step 3: For printing each layer, based on the generated printing trajectory, the XY moving platform first moves the initial printing point to the specified location on the XY plane;

[0065] 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 and generates ultrasonic waves. The ultrasonic transducer absorbs the ultrasonic waves and converts them into vibration energy. The ultrasonic vibration is transmitted to the metal wire wrapped in the wire feeding tube through the cylindrical connecting rod and vibrates back and forth along the axial direction of the cylindrical connecting rod.

[0066] Step 5: When the metal wire passes through the bottom of the wire feeding tube, it is heated by an 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 control system adjusts the real-time temperature of the electromagnetic induction heating device to soften the metal wire and assist the deposition process of the metal wire.

[0067] Step 6: When the metal wire moves downward at a certain feeding speed after ultrasonic resonance assistance and electromagnetic induction heating, it undergoes compressive stress deposition through a shear strain transfer device. The shear strain transfer 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 drive rod. The shear strain deposition head then applies stress to the metal wire that has been softened by electromagnetic induction heating and ultrasonic resonance, thereby realizing the connection between any unit of the metal wire and the adjacent and lower layers.

[0068] Step 7: After one unit deposition is completed, the shear strain transfer device is lifted along 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 deposited unit changes from the original circular cross section to a rectangular cross section.

[0069] Step 8: When switching to a new layer for printing or changing the printing direction, the control system issues a command to pause the feeding of the metal wire and the transmission of the shear strain deposition device; the shear strain deposition head moves in the Z direction via the Z-axis moving guide rail.

[0070] Step 9: Determine the wire feeding speed and shear strain transfer speed based on experimental experience. Simultaneously perform substrate preheating, ultrasonic vibration, and electromagnetic induction heating assistance while the metal wire is being fed in. Repeat the above steps after completing the deposition of one unit until solid-state connection of the workpiece is achieved.

[0071] The present invention will be further illustrated by a specific embodiment below.

[0072] The above-described apparatus is used to prepare TC4 quadrilateral square tube thin-walled parts.

[0073] The substrate used is a 40mm*40mm*8mm H13 tool steel plate. The titanium alloy wire is composed of 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.

[0074] First, the CAD model of the thin-walled quadrilateral tube is cut into multiple layers, each layer being a 4×4mm square. Based on the melting point of titanium alloy wire being 1650℃, its induction heating temperature and substrate preheating temperature are determined to be 1200℃ and 200℃, respectively.

[0075] Furthermore, based on the generated printing trajectory, the initial printing point of the XY moving 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 is passed through a hollow cylindrical shear strain transfer device with a diameter of 1 mm; the frequency of the ultrasonic vibration is 40 kHz, and the amplitude is 10 μm; the printing period of one unit by the shear strain transfer device is 0.025 s, and the oscillating shear displacement is 1 × 10⁻⁶. -4 m.

[0076] Furthermore, each system is activated, and ultrasonic resonance-assisted deposition of units is performed according to the generated printing trajectory and parameters. After the deposition of one unit is completed, the shear strain transfer device is raised by 0.25 mm on the X-axis and moved by 1 mm along the XY plane to deposit the next unit. The single layer thickness 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. The new layer repeats the above process according to the predetermined trajectory until the additive manufacturing of the quadrilateral square tube thin-walled part is completed.

[0077] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. An additive manufacturing device for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires, characterized in that: It includes a wire feeding system, a control system, an ultrasonic resonance system, an electromagnetic induction heating device, a triaxial moving device, a preheating substrate device, and a shear strain transfer device. The wire feeding system includes a wire feeding motor and a drive device; the wire feeding motor is placed outside the drive device to provide power, and the pre-tightening pressure bar on one side of the drive device acts on the pressure wheel to press the metal wire. The motor drives the driving wheel to rotate and drives the driven wheel to rotate, and the metal wire moves downward by friction. The drive device is connected to the Z-axis vertical mounting frame through two transverse connecting rods. The ultrasonic resonance system includes an ultrasonic generator, an ultrasonic transducer, a cylindrical connecting rod, and a ceramic piezoelectric element. The ultrasonic generator is mounted on a Z-axis transverse mounting bracket and is used to convert electrical energy into a high-frequency AC signal that matches the ultrasonic transducer. The ultrasonic transducer is fixed on the cylindrical connecting rod and connected to the ultrasonic generator via a wire. The right side of the cylindrical connecting rod is connected to the Z-axis transverse mounting bracket. The cylindrical connecting rod is hollow inside and has a ceramic piezoelectric element installed inside. The piezoelectric element generates a piezoelectric effect after current passes through it, which is used to transmit ultrasonic vibrations. Waveguide bushings are used to transmit and guide focused ultrasonic waves on metal wires; 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. 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 base plate. The base provides support and stability for the entire device and is fixed to the bottom of the device. The XY moving platform is mounted on the upper part of the base and is used to support the workpiece moving in the XY plane. The Z-axis moving guide rail is mounted on the Z-axis vertical mounting frame and is used to guide the movement of the workpiece along the Z-axis. The servo motor is mounted on the outside of the device and is used to provide power for the three-axis movement and provide real-time feedback of motion parameters. The transmission mechanism is connected to the XY moving platform and the Z-axis moving guide rail and is used to convert the rotational motion of the motor into linear motion. The base plate is used to support the deposited part and conduct heat to the deposited part. The preheating substrate device includes a heating power supply, a heating plate, and a temperature sensor; the heating power supply is installed on the outside of the substrate device to provide the energy required for heating; the heating plate is installed on the lower part of the substrate for heating and conducting heat; the temperature sensor is installed on the edge of the substrate to detect the temperature of the substrate in real time. The shear strain transfer device includes a shear strain drive rod, a sliding joint, a shear strain deposition head, and a Z-axis moving guide rail. The shear strain drive rod is mounted on the Z-axis moving guide rail and is used to transfer the force and motion of shear strain. The sliding joint is installed between the shear strain deposition head and the wire feeding tube and is used for the relative displacement between the wire feeding tube and the shear strain transfer device. The shear strain deposition head is located at the lower end of the wire feeding tube and is in contact with the sample, directly providing compressive stress. The control system can simultaneously control the wire feeding system, induction heating device, preheating substrate device, and ultrasonic resonance system, and adjust the wire feeding speed, induction heating temperature, substrate preheating temperature, ultrasonic frequency parameters, and shear strain transfer device operating frequency in real time for metal wire deposition. When the device is in operation, the substrate preheating temperature and electromagnetic induction heating temperature are first determined according to the melting point of the metal wire being processed. The appropriate wire feeding speed, shear strain transmission speed, and ultrasonic vibration frequency are adjusted to soften the metal wire and complete the wire deposition. During the additive manufacturing process, the electromagnetic induction heating device heats the metal wire by generating an induced current, softening the high-melting-point metal wire and promoting and assisting the solid-state deposition of the metal wire. Ultrasonic vibration is applied to provide energy to the metal wire and generate 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, promoting the metallurgical bonding of adjacent metal units.

2. A method of using the additive manufacturing apparatus for ultrasonic resonance-assisted direct deposition of high-melting-point metal wires as described in claim 1. Its features include the following steps: Step 1: Cut the CAD model into multiple layers, generate printing trajectories based on the shape of each layer, and determine the deposition path of the shear strain device; Step 2: Calculate and determine the induction heating temperature and substrate preheating temperature based on the melting point of the metal wire to be deposited; Step 3: For printing each layer, based on the generated printing trajectory, the XY moving platform first moves the initial printing 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 and generates ultrasonic waves. The ultrasonic transducer absorbs the ultrasonic waves and converts them into vibration energy. The ultrasonic vibration is transmitted to the metal wire wrapped in the wire feeding tube through the cylindrical connecting rod and vibrates back and forth along the axial direction of the cylindrical connecting rod. Step 5: When the metal wire passes through the bottom of the wire feeding tube, it is heated by an electromagnetic induction heating device. A high-temperature thermocouple is installed on the upper part of the electromagnetic induction heating device. The thermocouple detects the temperature of the metal wire and feeds it back to the control system. The control system adjusts the real-time temperature of the electromagnetic induction heating device 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 feeding speed after ultrasonic resonance assistance and electromagnetic induction heating, it undergoes compressive stress deposition through a shear strain transfer device. The shear strain transfer 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 drive rod. The shear strain deposition head then applies stress to the metal wire that has been softened by electromagnetic induction heating and ultrasonic resonance, realizing the connection between any unit of the metal wire and the adjacent and lower layers. Step 7: After one unit deposition is completed, the shear strain transfer device is lifted along 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 deposited unit changes from the original circular cross section to a rectangular cross section. Step 8: When switching to a new layer for printing or changing the printing direction, the control system issues a command to pause the feeding of the metal wire and the transmission of the shear strain deposition device; the shear strain deposition head moves in the Z direction via the Z-axis moving guide rail. Step 9: Determine the wire feeding speed and shear strain transfer speed based on experimental experience. Simultaneously perform substrate preheating, ultrasonic vibration, and electromagnetic induction heating assistance while the metal wire is being fed in. Repeat the above steps after completing the deposition of one unit until solid-state connection of the workpiece is achieved.

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