Aluminum alloy structure additive repair interface structure regulation and defect suppression device and method

Abstract

The invention discloses an aluminum alloy structure additive repair interface structure regulation and control and defect suppression device and method, and aims to solve the problem that coarse grains and interface defects are difficult to solve at the same time in a traditional additive repair method, and the refining of a repaired area structure and the suppression of defects are realized by combining metallurgical regulation and control and a high-frequency vibration technology. The method specifically comprises the steps that nanoscale rare earth particles are added into an aluminum alloy additive repairing material, and meanwhile a high-frequency vibration technology is applied to conduct real-time vibration treatment on a molten pool in the repairing process; the nano rare earth particles refine crystal grains, improve the liquidity of a molten pool and reduce generation of defects; the high-frequency vibration technology promotes uniform mixing of a molten pool, bubbles and inclusions are reduced, and the repairing quality is further improved; according to the method, the strength, hardness and corrosion resistance of the aluminum alloy repairing structure are remarkably improved, and the service life of a repairing part is prolonged. The invention belongs to the technical field of additive manufacturing.

Description

Technical Field

[0001] The present invention belongs to the technical field of additive manufacturing, and specifically relates to a device and method for regulating and controlling interface structure and suppressing defects of additive repair of aluminum alloy structures. Background Art

[0002] Aluminum alloys are widely used in aerospace, automobile manufacturing, mechanical engineering and other fields due to their excellent strength and lightweight properties. However, aluminum alloys may suffer various forms of damage during long-term use, especially under extreme working conditions, including wear, corrosion, fatigue cracks, etc. In order to extend the service life of aluminum alloy parts, additive repair is often required to restore their structure and function. Although additive repair technologies (such as laser cladding, electron beam melting, metal spraying, etc.) have been widely used in aluminum alloy repair, in practical applications, they still face the following major technical challenges:

[0003] 1. Repair the enlarged tissue in the area:

[0004] In the process of aluminum alloy additive repair, due to the uneven cooling rate and heat conduction of the molten pool, the grain size in the repair area is large. Coarse grains will reduce the strength, toughness and fatigue life of the material. According to the Grain Size-Strength relationship in materials science:

[0005] \sigma=\sigma_0+\frac{k}{d^{1 / 2}}

[0006] Among them, \(\sigma\) is the strength of the material, \(\sigma_0\) is the inherent strength of the material, \(k\) is the material constant, and \(d\) is the grain size. A larger grain size (\(d\)) will lead to a decrease in material strength, thus affecting the overall performance of the repair part.

[0007] 2. Interface defects:

[0008] During the additive repair process, defects such as bubbles, inclusions and cracks may appear at the interface between the repair material and the original aluminum alloy structure. These defects may be caused by incomplete gas discharge in the molten pool, uneven molten pool flow or uneven thermal stress. The presence of defects will not only reduce the density of the repaired area, but also affect its mechanical properties and corrosion resistance.

[0009] 3. Insufficient performance:

[0010] Traditional additive repair methods have limited effects in improving the strength and hardness of the repaired area. Existing technologies make it difficult to simultaneously optimize the strength, toughness and corrosion resistance of the repaired area, especially under high loads or harsh environments, where the repaired structure may not meet the use requirements. This results in the repaired aluminum alloy parts showing poor performance in actual applications, shortening their service life.

[0011] To address these challenges, researchers have tried a variety of methods to improve the quality of additive repair. However, traditional improvement measures, such as adjusting the melt pool temperature, controlling the cooling rate, or improving the melt pool atmosphere, often fail to completely solve the problems of coarse microstructure and interface defects. In summary, a new method is urgently needed to systematically improve the microstructure refinement and defect suppression in aluminum alloy additive repair, thereby improving the overall performance of the repaired area. Summary of the invention

[0012] In order to solve the problem that traditional additive repair methods are difficult to solve simultaneously the problem of coarse grains and interface defects, the present invention proposes an interface tissue regulation and defect suppression device and method for additive repair of aluminum alloy structures, which improves the tissue quality and performance of the repair area by combining nanoscale rare earth particles with high-frequency vibration technology.

[0013] The technical solution adopted by the present invention to solve the above problems is:

[0014] A device for controlling and suppressing interface organization and defects of additive repair of aluminum alloy structure comprises a planetary ball mill, a six-axis robot control cabinet, a six-axis robot, a laser cladding head, a laser cladding machine, a powder feeder, a gas cylinder, an ultrasonic generator and a heat treatment furnace, a horizontal ultrasonic vibrator and a vertical ultrasonic vibrator. The six-axis robot is connected to the six-axis robot control cabinet, the laser cladding head is installed on the six-axis robot, the position of the laser cladding head is adjusted by the six-axis robot, the laser cladding machine, the powder feeder and the gas cylinder are respectively connected to the laser cladding head, an aluminum alloy structural part to be processed is installed on a workbench through a clamp, the horizontal ultrasonic vibrator contacts the side end of the workbench through a horizontal ultrasonic vibration mounting frame, the vertical ultrasonic vibrator contacts the lower surface of the workbench through a vertical ultrasonic vibration mounting frame, and the horizontal ultrasonic vibrator and the vertical ultrasonic vibrator are connected to the ultrasonic generator.

[0015] Furthermore, the horizontal ultrasonic vibrator includes an ultrasonic tool head, an ultrasonic horn, a flange and an ultrasonic transducer. The upper end of the ultrasonic horn is connected to the lower end of the tool head, and the lower end of the ultrasonic horn is connected to the ultrasonic transducer through the flange. The vertical ultrasonic vibrator has the same structure as the horizontal ultrasonic vibrator.

[0016] Furthermore, the laser cladding head includes an optical fiber interface QBH, a CCD lens, a collimating protection lens, a collimating lens, a cooling system, a focusing lens, a focus adjustment knob, a focusing protection lens, a powder tube focus adjustment, a cladding four-way nozzle and a powder feeding connector. The optical fiber interface QBH, the collimating protection lens, the collimating lens, the focusing lens, the focusing protection lens, the powder tube focus adjustment and the cladding four-way nozzle are arranged in sequence from top to bottom, a focus adjustment knob is provided on the focusing lens, the CCD lens is installed on the side wall of the collimating lens, the cooling system is located at the bottom of the CCD lens, and a powder feeding connector is provided on the cladding four-way nozzle; the optical fiber interface QBH is connected to the laser cladding machine through an optical fiber, and the powder feeding connector is connected to the powder feeding machine through a pipeline.

[0017] A method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair is completed by the following steps:

[0018] Step 1: Adding nanometer-scale rare earth particles to the aluminum alloy additive repair material;

[0019] Step 2: Turn on the planetary ball mill, put the rare earth particles and the aluminum alloy additive repair material into the planetary ball mill, mix them thoroughly, take out the powder from the planetary ball mill after mixing evenly, and then put the mixed powder into the powder feeder;

[0020] Step 3: Open the six-axis robot control cabinet, laser cladding machine, powder feeder, gas cylinder, ultrasonic generator and set their respective process parameters;

[0021] Step 4: The aluminum alloy structural part to be processed is clamped on the workbench with a clamp, and the laser cladding head is driven by a six-axis robot to perform laser cladding additive repair on the aluminum alloy structural part, while the horizontal ultrasonic vibrator and the vertical ultrasonic vibrator apply ultrasonic vibration in the horizontal and vertical directions;

[0022] Step 5: After the aluminum alloy structural part is repaired by additive, it is placed in a heat treatment furnace for solution treatment and aging treatment;

[0023] Step 6. After completing the above steps 1 to 5, turn off the planetary ball mill, six-axis robot control cabinet, laser cladding machine, powder feeder, gas cylinder, ultrasonic generator and heat treatment furnace.

[0024] Furthermore, the particle size of the rare earth particles ranges from 1 to 100 nm, and the addition amount is 0.1% to 5% by mass.

[0025] Furthermore, the rare earth particles include, but are not limited to, neodymium, dysprosium, lanthanum and combinations thereof.

[0026] Furthermore, the frequency range of the horizontal ultrasonic vibrator and the vertical ultrasonic vibrator is 20kHz to 1MHz, and the amplitude range is 0.1mm to 1mm.

[0027] Furthermore, the temperature range of the solution treatment is 450°C to 550°C, and the treatment time is 0.5 hours to 2 hours; the temperature range of the aging treatment is 180°C to 220°C, and the treatment time is 2 hours to 10 hours.

[0028] Furthermore, the laser power range of the laser cladding machine is 100-4000W, and the powder hopper of the powder feeder has an automatic drying function, with a maximum drying temperature of 120°C.

[0029] Furthermore, the additive repair material is aluminum alloy powder or wire.

[0030] The beneficial effects of the present invention are:

[0031] 1. Microstructure refinement: The present invention combines nano rare earth particles with high-frequency vibration technology to effectively refine the grains in the repaired area, significantly improving the strength and toughness of the aluminum alloy material;

[0032] 2. Defect suppression: The present invention can reduce bubbles and inclusions in the molten pool through high-frequency vibration technology, reduce the generation of interface defects, and improve the quality of the repair area;

[0033] 3. Performance improvement: The aluminum alloy structure repaired by the present invention exhibits higher strength, hardness and corrosion resistance, extending the service life of the repaired parts. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the overall structure of the device part of the present invention;

[0035] Figure 2 It is a schematic diagram of the structure of the ultrasonic vibration component of the present invention;

[0036] Figure 3 It is a structural schematic diagram of the laser cladding head of the present invention.

[0037] In the figure, 1- planetary ball mill; 2- six-axis robot control cabinet; 3- six-axis robot; 4- laser cladding head; 4-1- optical fiber interface QBH; 4-2- CCD lens; 4-3- collimation protection lens; 4-4- collimation lens; 4-5- cooling system; 4-6- focusing lens; 4-7- focus adjustment knob; 4-8- focusing protection lens; 4-9- powder tube focus adjustment; 4-10- cladding four-way nozzle; 4-11- powder delivery connector; 5-aluminum alloy structural parts; 6-fixture; 7-workbench; 8-laser cladding machine; 9-powder feeder; 10-gas cylinder; 11-ultrasonic generator; 12-heat treatment furnace; 13-horizontal ultrasonic vibration device; 13-1-ultrasonic tool head; 13-2-ultrasonic amplitude transformer; 13-3-flange; 13-4-ultrasonic transducer; 14-horizontal ultrasonic vibration device mounting frame; 15-vertical ultrasonic vibration device mounting frame; 16-vertical ultrasonic vibration device. DETAILED DESCRIPTION

[0038] Specific implementation method 1: Combination Figure 1 The present embodiment is described. The present embodiment describes an interface organization regulation and defect suppression device for additive repair of an aluminum alloy structure, which includes a planetary ball mill 1, a six-axis robot control cabinet 2, a six-axis robot 3, a laser cladding head 4, a laser cladding machine 8, a powder feeder 9, a gas cylinder 10, an ultrasonic generator 11, a heat treatment furnace 12, a horizontal ultrasonic vibrator 13, and a vertical ultrasonic vibrator 16. The six-axis robot 3 is connected to the six-axis robot control cabinet 2. The laser cladding head 4 is installed on the six-axis robot 3. The position of the laser cladding head 4 is adjusted by the six-axis robot 3. The laser cladding machine 8, the powder feeder 9, and the gas cylinder 10 are respectively connected to the laser cladding head 4. The aluminum alloy structural part 5 to be processed is installed on the workbench 7 through a clamp 6. The horizontal ultrasonic vibrator 13 contacts the side end of the workbench through a horizontal ultrasonic vibration mounting frame 14. The vertical ultrasonic vibrator 16 contacts the lower surface of the workbench through a vertical ultrasonic vibration mounting frame. The horizontal ultrasonic vibrator 13 and the vertical ultrasonic vibrator 16 are connected to the ultrasonic generator 11.

[0039] Specific implementation method 2: Combination Figure 2 This embodiment is described. The horizontal ultrasonic vibrator 13 of this embodiment includes an ultrasonic tool head 13-1, an ultrasonic horn 13-2, a flange 13-3 and an ultrasonic transducer 13-4. The upper end of the ultrasonic horn 13-2 is connected to the lower end of the tool head 13-1, and the lower end of the ultrasonic horn 13-2 is connected to the ultrasonic transducer 13-4 through the flange 13-3. The vertical ultrasonic vibrator 16 has the same structure as the horizontal ultrasonic vibrator 13. The other components and connection relationships of this embodiment are the same as those of the first embodiment.

[0040] Specific implementation method three: Combination Figure 3The present embodiment is described. The laser cladding head 4 in the present embodiment includes an optical fiber interface QBH4-1, a CCD lens 4-2, a collimating protection lens 4-3, a collimating lens 4-4, a cooling system 4-5, a focusing lens 4-6, a focus adjustment knob 4-7, a focusing protection lens 4-8, a powder tube focus adjustment 4-9, a cladding four-way nozzle 4-10 and a powder feeding connector 4-11. The optical fiber interface QBH4-1, the collimating protection lens 4-3, the collimating lens 4-4, the focusing lens 4-6, the focusing protection lens 4-8, the powder tube focus adjustment 4-9 and the cladding four-way nozzle 4-10 are composed of From top to bottom, the focusing lens 4-6 is provided with a focus adjustment knob 4-7, the CCD lens 4-2 is installed on the side wall of the collimating lens 4-4, the cooling system 4-5 is located at the bottom of the CCD lens 4-2, and the cladding four-way nozzle 4-10 is provided with a powder feeding connector 4-11; the optical fiber interface QBH4-1 is connected to the laser cladding machine 8 through an optical fiber, and the laser cladding machine 8 provides energy to the laser cladding head 4, and the powder feeding connector 4-11 is connected to the powder feeder 9 through a pipeline, and the powder feeder 9 provides the laser cladding head 4 with powder for additive repair. The other components and connection relationships of this embodiment are the same as those of the first or second embodiment.

[0041] Specific implementation method 4: The method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair described in this implementation method is completed by the following steps:

[0042] Step 1: Add nanometer-scale rare earth particles to the aluminum alloy additive repair material to refine the grains in the repair area, improve the fluidity of the molten pool, and inhibit the generation of defects. During the additive repair process, the molten pool is vibrated in real time through high-frequency vibration technology to promote uniform mixing of the molten pool, reduce bubbles and inclusions, and improve the density and uniformity of the repair area.

[0043] Step 2: Open the planetary ball mill 1, put the rare earth particles and the aluminum alloy additive repair material into the planetary ball mill 1, mix them thoroughly, take out the powder from the planetary ball mill 1 after mixing evenly, and then put the mixed powder into the powder feeder 9;

[0044] Step 3: Open the six-axis robot control cabinet 2, the laser cladding machine 8, the powder feeder 9, the gas cylinder 10, and the ultrasonic generator 11 and set appropriate process parameters for each;

[0045] Step 4: The aluminum alloy structural part 5 to be processed is clamped on the workbench 7 by using a clamp 6, and the laser cladding head 4 is driven by the six-axis robot 3 to perform laser cladding additive repair on the aluminum alloy structural part 5, while the horizontal ultrasonic vibrator 13 and the vertical ultrasonic vibrator 16 apply ultrasonic vibrations in both horizontal and vertical directions;

[0046] During the repair process, the vibration of the molten pool is carried out synchronously with the deposition process of the material to achieve the best organizational refinement and defect suppression effect. During the high-frequency vibration treatment, the vibration amplitude and frequency of the molten pool are controlled to maintain the stability of the molten pool and optimize the fluidity of the molten pool. By analyzing the microstructure, mechanical properties and defect distribution of the repair area, the type and addition amount of rare earth particles, as well as the parameter setting of high-frequency vibration, are optimized.

[0047] In the process of additive repair, high-frequency vibration technology is applied to perform real-time vibration treatment on the molten pool. This treatment can promote uniform mixing of the molten pool, reduce bubbles and inclusions, and thus improve the density and uniformity of the repaired area. The effect of high-frequency vibration on the molten pool can be described by the following relationship:

[0048] \DeltaP = \eta\cdotA\cdot f

[0049] Among them, \(\DeltaP\) is the pressure change of the molten pool due to vibration, \(\eta\) is the vibration transmission efficiency, \(A\) is the vibration amplitude, and \(f\) is the vibration frequency. By adjusting the vibration frequency and amplitude, the bubbles and inclusions in the molten pool can be effectively reduced, the fluidity and mixing effect of the molten pool can be optimized, and the quality of the repair area can be improved.

[0050] Step 5: After the aluminum alloy structural part 5 is repaired by additive, it is placed in a heat treatment furnace 12 for solution treatment and aging treatment;

[0051] Step 6: After completing the above steps 1 to 5, turn off the planetary ball mill 1, the six-axis robot control cabinet 2, the laser cladding machine 8, the powder feeder 9, the gas cylinder 10, the ultrasonic generator 11 and the heat treatment furnace 12.

[0052] Specific implementation method 5: The particle size range of the rare earth particles described in this implementation method is 1-100 nm, and the addition amount is 0.1% to 5% by mass.

[0053] Its grain refining effect is based on the theory of nanoparticle refinement mechanism. According to research, these nanoparticles can effectively reduce the grain size, thereby improving the mechanical properties of aluminum alloys. This effect can be understood by the relationship between grain size and nanoparticle diameter:

[0054] d=\frac{K\cdot\lambda}{\sigma_{grain}}

[0055] Wherein, \(d\) is the grain size, \(K\) is the material characteristic constant, \(\lambda\) is the diameter of the rare earth particles, and \(\sigma_{grain}\) is the internal stress of the grain. By introducing nanoparticles, the grains in the repaired area can be effectively refined, and the strength and toughness of the material can be improved. The other components and connection relationships of this embodiment are the same as those of the fourth embodiment.

[0056] Specific embodiment 6: The selection of the rare earth particles described in this embodiment includes but is not limited to neodymium, dysprosium, lanthanum and their combination. The other components and connection relationships of this embodiment are the same as those of specific embodiment 4 or 5.

[0057] Specific embodiment seven: The frequency range of the horizontal ultrasonic vibrator 13 and the vertical ultrasonic vibrator 16 in this embodiment is 20kHz to 1MHz, and the amplitude range is 0.1mm to 1mm. The ultrasonic vibrator adopts an ultrasonic vibrator or a high-frequency electromagnetic vibration device. The application mode of the high-frequency vibration technology in the additive repair process is continuous vibration or periodic vibration, and the specific parameters are adjusted according to the actual state of the molten pool and the repair requirements. The other components and connection relationships of this embodiment are the same as those of specific embodiments four, five or six.

[0058] Specific embodiment eight: The temperature range of the solution treatment described in this embodiment is 450°C to 550°C, and the treatment time is 0.5 hours to 2 hours; the temperature range of the aging treatment is 180°C to 220°C, and the treatment time is 2 hours to 10 hours. The other components and connection relationships of this embodiment are the same as those of specific embodiments four, five, six or seven.

[0059] Specific embodiment 9: The laser power range of the laser cladding machine 8 in this embodiment is 100-4000W, and the powder hopper of the powder feeder 9 has an automatic drying function, and the maximum drying temperature is 120° C. The other components and connection relationships of this embodiment are the same as those of specific embodiments 4, 5, 6, 7 or 8.

[0060] Specific embodiment 10: The additive repair material described in this embodiment is aluminum alloy powder or wire. The rare earth particles are evenly distributed in the aluminum alloy powder or wire. If it is aluminum alloy powder, the powder feeder 9 is used to supply powder during additive repair. If aluminum alloy wire is used, the powder feeder 9 is changed to a wire feeder to supply wire during additive repair. The other components and connection relationships of this embodiment are the same as those of specific embodiments 4, 5, 6, 7, 8 or 9.

[0061] Specific embodiment eleven: The additive manufacturing repair method described in this embodiment is not limited to the above-mentioned laser additive manufacturing repair, but also includes arc additive manufacturing repair and electron beam additive manufacturing repair. The other components and connection relationships of this embodiment are the same as those of specific embodiments four, five, six, seven, eight, nine or ten.

[0062] Example 1: Application of the addition of neodymium (Nd) rare earth particles combined with ultrasonic vibration

[0063] S1, select standard aluminum alloy powder as a substrate with a particle size of 50-100 μm, select neodymium (Nd) as a rare earth element, purchase neodymium particles with a particle size of 10-50 nm, and the mixing ratio is 0.5% (mass percentage), turn on the planetary ball mill 1, put the neodymium particles and the aluminum alloy powder into the planetary ball mill 1 for full mixing to ensure that the rare earth particles are evenly distributed in the aluminum alloy powder, and then put the mixed powder into the powder feeder 9;

[0064] S2, open the six-axis robot control cabinet 2, open the laser cladding machine 8, set the laser power to 2500W, the laser scanning speed to 900mm / min, open the powder feeder 9, set the powder feeding rate to 0.6r / min, open the gas cylinder 10 and set the protective gas flow rate to 10L / min, the protective gas used is argon, open the ultrasonic generator 11 and set the ultrasonic vibration frequency to 100kHz and the amplitude to 0.5mm;

[0065] S3, the aluminum alloy structural part 5 is clamped on the workbench 7 by the clamp 6, and the laser cladding head 4 is driven by the six-axis robot 3 to perform laser cladding additive repair on the aluminum alloy structural part 5, while the ultrasonic vibration device 13 and the ultrasonic vibration device 16 apply ultrasonic vibration in the horizontal and vertical directions, and deposit materials layer by layer according to the design requirements of the repair area, and monitor the temperature, pressure and other key parameters during the process;

[0066] S4, after the aluminum alloy structural part 5 is repaired by additive, it is placed in a heat treatment furnace 12 for solution treatment, heated to 500°C, kept at this temperature for 1 hour, and then water quenched. This process helps to eliminate the internal stress generated in the aluminum alloy due to rapid solidification;

[0067] S5, after the aluminum alloy structural part 5 is solution treated, it is placed in a heat treatment furnace 12 for aging treatment, heated to 200°C, kept at this temperature for 6 hours, and then air-cooled to further improve the mechanical properties and corrosion resistance of the repaired area;

[0068] S6, when all the work is completed, turn off the planetary ball mill 1, the six-axis robot control cabinet 2, the laser cladding machine 8, the powder feeder 9, the gas cylinder 10, the ultrasonic generator 11 and the heat treatment furnace 12.

[0069] Example 1 proves that the interface structure of the aluminum alloy structure additive repair is significantly refined, defects such as pores are significantly reduced, and the mechanical properties of the aluminum alloy structure additive repair interface are also improved.

[0070] Example 2: Application of the addition of dysprosium (Dy) rare earth particles combined with ultrasonic vibration

[0071] S1, select standard aluminum alloy powder as the base material, with a particle size of 30-80 μm, select dysprosium Dy as the rare earth element, purchase dysprosium particles with a particle size of 20-70 nm, and the mixing ratio is 1% by mass, turn on the planetary ball mill 1, put the dysprosium particles and the aluminum alloy powder into the planetary ball mill 1 for full mixing to ensure that the rare earth particles are evenly distributed in the aluminum alloy powder, and then put the mixed powder into the powder feeder 9;

[0072] S2, open the six-axis robot control cabinet 2, open the laser cladding machine 8, set the laser power to 1500W, the laser scanning speed to 450mm / min, open the powder feeder 9, set the powder feeding rate to 0.4r / min, open the gas cylinder 10 and set the protective gas flow rate to 10L / min, the protective gas used is argon, open the ultrasonic generator 11 and set the ultrasonic vibration frequency to 40kHz and the amplitude to 0.3mm;

[0073] S3, the aluminum alloy structural part 5 is clamped on the workbench 7 by the clamp 6, and the laser cladding head 4 is driven by the six-axis robot 3 to perform laser cladding additive repair on the aluminum alloy structural part 5, while the ultrasonic vibration device 13 and the ultrasonic vibration device 16 apply ultrasonic vibration in the horizontal and vertical directions, and deposit materials layer by layer according to the design requirements of the repair area, and monitor the temperature, pressure and other key parameters during the process;

[0074] S4, after the aluminum alloy structural part 5 is repaired by additive, it is placed in the heat treatment furnace 12 for solution treatment, heated to 480°C, kept at this temperature for 1 hour, and then water quenched. This process helps to eliminate the internal stress generated in the aluminum alloy due to rapid solidification;

[0075] S5, after the aluminum alloy structural part 5 is solution treated, it is placed in a heat treatment furnace 12 for aging treatment, heated to 220°C, kept warm for 4 hours and then air-cooled to further improve the mechanical properties and corrosion resistance of the repaired area;

[0076] S6, when all the work is completed, turn off the planetary ball mill 1, the six-axis robot control cabinet 2, the laser cladding machine 8, the powder feeder 9, the gas cylinder 10, the ultrasonic generator 11 and the heat treatment furnace 12.

[0077] As demonstrated in Example 2, the structure of the interface of the aluminum alloy structure additive repair is significantly refined, defects such as pores are significantly reduced, and the mechanical properties of the interface of the aluminum alloy structure additive repair are also improved.

[0078] Example 3: Application of the addition of neodymium-dysprosium (Nd-Dy) mixed rare earth particles combined with ultrasonic vibration

[0079] S1, select standard aluminum alloy powder as a base material with a particle size of 40-90 μm, select neodymium (Nd) and dysprosium (Dy) as rare earth elements, purchase neodymium particles with a particle size of 10-30 nm and dysprosium particles with a particle size of 20-50 nm respectively, mix the neodymium particles and dysprosium particles in a mass ratio of 1:1, and add 0.8% (mass percentage), turn on the planetary ball mill 1, put the neodymium particles and dysprosium particles and the aluminum alloy powder into the planetary ball mill 1 for full mixing to ensure that the rare earth particles are evenly distributed in the aluminum alloy powder, and then put the mixed powder into a powder feeder 9;

[0080] S2, open the six-axis robot control cabinet 2, open the laser cladding machine 8, set the laser power to 2000W, the laser scanning speed to 600mm / min, open the powder feeder 9, set the powder feeding rate to 0.5r / min, open the gas cylinder 10 and set the protective gas flow rate to 10L / min, the protective gas used is argon, open the ultrasonic generator 11 and set the ultrasonic vibration frequency to 60kHz and the amplitude to 0.4mm;

[0081] S3, the aluminum alloy structural part 5 is clamped on the workbench 7 by the clamp 6, and the laser cladding head 4 is driven by the six-axis robot 3 to perform laser cladding additive repair on the aluminum alloy structural part 5, while the ultrasonic vibration device 13 and the ultrasonic vibration device 16 apply ultrasonic vibration in the horizontal and vertical directions, and deposit materials layer by layer according to the design requirements of the repair area, and monitor the temperature, pressure and other key parameters during the process;

[0082] S4, after the aluminum alloy structural part 5 is repaired by additive, it is placed in the heat treatment furnace 12 for solution treatment, heated to 520°C, kept at this temperature for 1 hour, and then water quenched. This process helps to eliminate the internal stress generated in the aluminum alloy due to rapid solidification;

[0083] S5, after the aluminum alloy structural part 5 is solution treated, it is placed in a heat treatment furnace 12 for aging treatment, heated to 190°C, kept warm for 6 hours, and then air-cooled to further improve the mechanical properties and corrosion resistance of the repaired area;

[0084] S6, when all the work is completed, turn off the planetary ball mill 1, the six-axis robot control cabinet 2, the laser cladding machine 8, the powder feeder 9, the gas cylinder 10, the ultrasonic generator 11 and the heat treatment furnace 12.

[0085] As demonstrated in Example 3, the microstructure of the interface of the aluminum alloy structure additive repair is significantly refined, defects such as pores are significantly reduced, and the mechanical properties of the interface of the aluminum alloy structure additive repair are also improved.

[0086] The above is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technician familiar with this profession can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any simple modification, equivalent replacement and improvement made to the above embodiments without departing from the content of the technical solution of the present invention, based on the technical essence of the present invention, within the spirit and principles of the present invention, still fall within the protection scope of the technical solution of the present invention.

Claims

1. A device for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair, comprising a planetary ball mill (1), a six-axis robot control cabinet (2), a six-axis robot (3), a laser cladding machine (8), a powder feeder (9), a gas cylinder (10), an ultrasonic generator (11) and a heat treatment furnace (12), characterized in that: The device for controlling the interface structure and suppressing defects of an aluminum alloy structure by additive repair also includes a laser cladding head (4), a horizontal ultrasonic vibrator (13), a horizontal ultrasonic vibration mounting frame (14), a vertical ultrasonic vibration mounting frame (15) and a vertical ultrasonic vibrator (16); the six-axis robot (3) is connected to a six-axis robot control cabinet (2); the laser cladding head (4) is mounted on the six-axis robot (3); the position of the laser cladding head (4) is adjusted by the six-axis robot (3); the laser cladding machine (8), A powder feeder (9) and a gas cylinder (10) are respectively connected to a laser cladding head (4); an aluminum alloy structural part (5) to be processed is mounted on a workbench (7) via a fixture (6); a horizontal ultrasonic vibrator (13) contacts the side end of the workbench (7) via a horizontal ultrasonic vibration mounting frame (14); a vertical ultrasonic vibrator (16) contacts the lower surface of the workbench (7) via a vertical ultrasonic vibration mounting frame (15); and the horizontal ultrasonic vibrator (13) and the vertical ultrasonic vibrator (16) are connected to an ultrasonic generator (11).

2. The device for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 1, characterized in that: The horizontal ultrasonic vibrator (13) comprises an ultrasonic tool head (13-1), an ultrasonic horn (13-2), a flange (13-3) and an ultrasonic transducer (13-4); the upper end of the ultrasonic horn (13-2) is connected to the lower end of the tool head (13-1); the lower end of the ultrasonic horn (13-2) is connected to the ultrasonic transducer (13-4) via the flange (13-3); and the vertical ultrasonic vibrator (16) has the same structure as the horizontal ultrasonic vibrator (13).

3. The device for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 1, characterized in that: The laser cladding head (4) comprises an optical fiber interface QBH (4-1), a CCD lens (4-2), a collimating protective lens (4-3), a collimating lens (4-4), a cooling system (4-5), a focusing lens (4-6), a focus adjustment knob (4-7), a focusing protective lens (4-8), a powder tube focus adjustment (4-9), a cladding four-way nozzle (4-10) and a powder delivery connector (4-11), an optical fiber interface QBH (4-1), a collimating protective lens (4-3), a collimating lens (4-4), a focusing lens (4-6), and a focusing protective lens (4-8) , a powder tube focus adjustment (4-9) and a cladding four-way nozzle (4-10) are arranged in sequence from top to bottom, a focus adjustment knob (4-7) is provided on the focusing lens (4-6), a CCD lens (4-2) is installed on the side wall of the collimating lens (4-4), a cooling system (4-5) is located at the lower part of the CCD lens (4-2), and a powder feeding connector (4-11) is provided on the cladding four-way nozzle (4-10); the optical fiber interface QBH (4-1) is connected to the laser cladding machine (8) through an optical fiber, and the powder feeding connector (4-11) is connected to the powder feeding machine (9) through a pipeline.

4. A method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair, characterized in that: The method is completed by the following steps: Step 1: Adding nanometer-scale rare earth particles to the aluminum alloy additive repair material; Step 2: Open the planetary ball mill (1), put the rare earth particles and the aluminum alloy additive repair material into the planetary ball mill (1), mix them thoroughly, take out the powder from the planetary ball mill (1) after mixing evenly, and then put the mixed powder into the powder feeder (9); Step 3: Turn on the six-axis robot control cabinet (2), the laser cladding machine (8), the powder feeder (9), the gas cylinder (10) and the ultrasonic generator (11), and set their respective process parameters; Step 4: The aluminum alloy structural part (5) to be processed is clamped on the workbench (7) by a clamp (6), and the laser cladding head (4) is driven by the six-axis robot (3) to perform laser cladding additive repair on the aluminum alloy structural part (5), while the horizontal ultrasonic vibrator (13) and the vertical ultrasonic vibrator (16) apply ultrasonic vibration in the horizontal and vertical directions; Step 5: After the aluminum alloy structural part (5) is repaired by additive manufacturing, it is placed in a heat treatment furnace (12) for solution treatment and aging treatment; Step 6: After completing the above steps 1 to 5, turn off the planetary ball mill (1), the six-axis robot control cabinet (2), the laser cladding machine (8), the powder feeder (9), the gas cylinder (10), the ultrasonic generator (11) and the heat treatment furnace (12).

5. The method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 4, characterized in that: The particle size of the rare earth particles ranges from 1 to 100 nm, and the addition amount is 0.1% to 5% by mass.

6. A method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 4 or 5, characterized in that: The selection of rare earth particles includes, but is not limited to, neodymium, dysprosium, lanthanum, and combinations thereof.

7. The method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 4, characterized in that: The frequency range of the horizontal ultrasonic vibrator (13) and the vertical ultrasonic vibrator (16) in step 4 is 20kHz to 1MHz, and the amplitude range is 0.1mm to 1mm.

8. The method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 4, characterized in that: The temperature range of the solution treatment in step five is 450° C. to 550° C., and the treatment time is 0.5 to 2 hours; the temperature range of the aging treatment is 180 to 220° C., and the treatment time is 2 to 10 hours.

9. The method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 4, characterized in that: The laser power range of the laser cladding machine (8) is 100-4000W, and the powder hopper of the powder feeder (9) has an automatic drying function, with a maximum drying temperature of 120°C.

10. The method for controlling the interface structure and suppressing defects of aluminum alloy structure additive repair according to claim 4, characterized in that: The additive repair material is aluminum alloy powder or wire.

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