A method for additive manufacturing high-performance aluminum-based composite materials using bilayer composite filaments and electromagnetic field modulation.

Abstract

The present invention relates to the technical field of aluminum-based composite materials, and in particular to a method for manufacturing high-performance aluminum-based composite materials by adding a double-layer composite wire and electromagnetic field control thereof, comprising the following steps: (1) preparing a double-layer composite wire; (2) using a triaxial electromagnetic field to control the additive manufacturing process; and (3) post-processing the obtained aluminum-based composite material. The core Al-Ti-B alloy provides an ideal reaction environment for the in-situ generation of TiB2 nanophases, while the shell Al-Cu-Mg alloy provides solid solution strengthening elements for the matrix. This layered design not only achieves the spatial separation of the reinforcing phase and the solid solution strengthening elements, but also creates conditions for the synergistic effect of the two strengthening mechanisms. Secondly, the introduction of triaxial electromagnetic field control technology provides a powerful tool for the precise control of the molten pool behavior. By independently controlling the magnetic field intensity and frequency in the x, y, and z directions, multi-dimensional control of the molten pool flow, heat transfer, and solidification behavior can be achieved.

Description

Technical Field

[0001] This invention relates to the field of aluminum-based composite materials technology, and more particularly to a double-layer composite filament and a method for electromagnetically controlled additive manufacturing of high-performance aluminum-based composite materials. Background Technology

[0002] With the increasing demand for high-performance lightweight materials in aerospace, automotive, and electronic packaging industries, aluminum matrix composites have attracted widespread attention due to their excellent specific strength and specific modulus. However, traditional methods for preparing aluminum matrix composites face many challenges, such as uneven distribution of reinforcing phases, low interfacial bonding strength, and high residual stress. These problems severely restrict further improvements in material performance.

[0003] In recent years, the rapid development of additive manufacturing technology has provided new avenues for the preparation of high-performance metallic materials. However, existing metal additive manufacturing technologies still face many limitations when processing aluminum-based composite materials. First, traditional single-layer alloy wires are difficult to control precisely across multiple components, leading to uneven distribution of the reinforcing phase. Second, in conventional laser cladding processes, the flow behavior of the molten pool is difficult to precisely control, which not only affects the distribution of the reinforcing phase but also easily leads to the formation of defects such as porosity and cracks. Furthermore, existing technologies struggle to simultaneously achieve uniform distribution of the nano-reinforcing phase and sufficient solid solution of the matrix alloying elements, limiting the material's strengthening effect.

[0004] In view of the above problems, there is an urgent need for novel preparation methods that can achieve precise design and control of the microstructure of aluminum-based composite materials, while improving the overall performance of the materials. This invention is proposed against this background, aiming to overcome the limitations of existing technologies and provide an innovative solution for the preparation of high-performance aluminum-based composite materials. Summary of the Invention

[0005] The core innovation of this invention lies in the unique combination of a double-layer composite filament structure and a triaxial electromagnetic field-controlled additive manufacturing method. This innovative design not only overcomes many difficulties in existing technologies but also brings a series of unexpected technical effects.

[0006] The purpose of this invention is to provide a method for additive manufacturing high-performance aluminum-based composite materials using a double-layer composite filament and electromagnetic field modulation, comprising the following steps:

[0007] (1) Preparation of double-layer composite filament;

[0008] (2) Using triaxial electromagnetic fields to control the additive manufacturing process;

[0009] (3) Post-processing of the obtained aluminum-based composite material.

[0010] Preferably, the method for preparing the double-layer composite filament in step (1) includes:

[0011] (a) Preparing the core alloy, including the following steps:

[0012] First, pure aluminum ingots with a purity of ≥99.99% are placed in a graphite crucible and heated to 700-750℃ under argon protection to melt them;

[0013] Next, add a predetermined amount of titanium powder with a purity ≥99.5% and boron powder with a purity ≥99.5%, stir at 300-400 rpm, and maintain for 30-60 minutes;

[0014] Then, the melt is poured into a metal mold preheated to 200-250°C and cooled to room temperature;

[0015] (b) Preparing the shell alloy, including the following steps:

[0016] First, place pure aluminum ingots with a purity of ≥99.99% in another graphite crucible and heat them to 700-750℃ under argon protection to melt them;

[0017] Next, add the predetermined amounts of copper granules with a purity ≥99.9% and magnesium ingots with a purity ≥99.9% in sequence, and stir at 300-400 rpm for 20-40 minutes.

[0018] Then, the melt is poured into a metal mold preheated to 200-250°C and cooled to room temperature;

[0019] (c) The core alloy and the shell alloy are respectively machined into round bars with a diameter of 8-10 mm;

[0020] (d) The shell alloy round bar is machined into a hollow round tube with an inner diameter slightly larger than that of the core alloy round bar;

[0021] (e) Insert the core alloy round bar into the shell alloy hollow round tube to ensure that the two fit tightly together;

[0022] (f) Place the assembled double-layer structure in a vacuum hot isostatic pressing equipment and maintain it at 500-550℃ and 100-150MPa for 2-4 hours.

[0023] (g) The double-layer composite material after hot isostatic pressing is subjected to multiple hot extrusions and cold stretchings to finally obtain a double-layer composite filament with a diameter of 1.2-1.6 mm.

[0024] Preferably, the composition of the core alloy is:

[0025] Aluminum: 92.5-96.0% by weight

[0026] Titanium: 3.0-6.0% by weight

[0027] Boron: 0.5-1.5% by weight.

[0028] Preferably, the composition of the shell alloy is:

[0029] Aluminum: 93.0-96.5% by weight

[0030] Copper: 2.5-5.0% by weight

[0031] Magnesium: 1.0-2.5% by weight.

[0032] Preferably, step (2) of controlling the additive manufacturing process using a triaxial electromagnetic field includes the following steps:

[0033] (a) Equipment preparation:

[0034] A fiber laser with a power of 1000-1500W is used as the heat source;

[0035] Design and install a triaxial electromagnetic field generator capable of independently generating magnetic field strengths of 0.2-0.5T in the x, y, and z directions;

[0036] Prepare an additive manufacturing chamber with inert gas protection.

[0037] (b) Process parameter settings:

[0038] Laser power: 800-1200W;

[0039] Scanning speed: 600-1000 mm / min;

[0040] Wire feeding speed: 1500-2500 mm / min;

[0041] Layer thickness: 0.2-0.4mm;

[0042] Argon flow rate: 15-25 L / min;

[0043] Substrate preheating temperature: 150-200℃;

[0044] (c) Electromagnetic field parameter settings:

[0045] x-axis magnetic field strength: 0.2-0.3T;

[0046] y-axis magnetic field strength: 0.3-0.4T;

[0047] z-axis magnetic field strength: 0.4-0.5T;

[0048] Magnetic field frequency: 10-50Hz;

[0049] (d) Manufacturing process:

[0050] First, load the double-layer composite filament into the filament feeding device;

[0051] Next, activate the inert gas protection system to fill the molding chamber with argon gas; then, preheat the substrate to the set temperature.

[0052] Next, start the triaxial electromagnetic field system;

[0053] Next, the laser scanning and wire feeding process begins, and layer-by-layer deposition is performed; after each layer is deposited, a cooling time of 20-30 seconds is maintained.

[0054] Repeat the above process until the entire part is manufactured.

[0055] Preferably, the post-processing in step (3) includes the following steps: (a) cooling the manufactured part to room temperature in an inert gas environment; (b) performing a T6 heat treatment, including:

[0056] Solution treatment: 530-550℃, hold for 1-2 hours;

[0057] Quenching: Water quenching to room temperature;

[0058] Aging treatment: 160-180℃, keep for 6-8 hours.

[0059] Preferably, the method further includes the following control points:

[0060] (a) In-situ generation control of TiB2:

[0061] Reaction temperature: 700-750℃;

[0062] Reaction time: 30-60 minutes;

[0063] Stirring speed: 300-400 rpm;

[0064] Cooling rate: >50℃ / s;

[0065] (b) Cu-Mg solid solution strengthening control:

[0066] Solution treatment temperature: 530-550℃;

[0067] Solution treatment time: 1-2 hours;

[0068] Quenching medium: water (temperature: 20-25℃);

[0069] Aging temperature: 160-180℃;

[0070] Delivery time: 6-8 hours;

[0071] (c) Electromagnetic field manipulation:

[0072] Magnetic field strength range: 0.2-0.5T;

[0073] Magnetic field frequency: 10-50Hz;

[0074] Magnetic field direction: independently controlled along the x, y, and z axes;

[0075] Magnetic field waveform: sine wave;

[0076] (d) Porosity control:

[0077] Inert gas purity: ≥99.999%;

[0078] Gas flow rate: 15-25 L / min;

[0079] Molding chamber pressure: 1.1-1.2 standard atmospheres;

[0080] Melt pool temperature: 660-720℃.

[0081] Preferably, the method further includes the following steps:

[0082] In the additive manufacturing process, after each layer is deposited, an eddy current flaw detector is used to perform real-time non-destructive testing on the deposited layer. The testing frequency is 1-5MHz and the scanning speed is 50-100mm / s.

[0083] Preferably, the method further includes the following steps:

[0084] After T6 heat treatment, the resulting aluminum-based composite material undergoes surface treatment, including:

[0085] First, sandblasting is performed using alumina sand with a particle size of 80-120 mesh and a sandblasting pressure of 0.4-0.6 MPa.

[0086] Secondly, anodizing is performed in a 20wt% sulfuric acid solution at a current density of 1-2 A / dm³. 2 The temperature is 18-22℃, and the time is 30-60 minutes;

[0087] Finally, seal the holes by soaking them in boiling water for 15-30 minutes.

[0088] Preferably, the method further includes the following steps:

[0089] During the additive manufacturing process, a high-speed camera is used to monitor the state of the molten pool in real time. The camera has a frame rate of 1000-2000fps and a resolution of no less than 1280x1024 pixels. Based on the image analysis results, the laser power and wire feeding speed are adjusted in real time at a frequency of 10-20Hz.

[0090] First, the design of the double-layer composite wire ingeniously solves the problem of precise control of multiple components. The Al-Ti-B alloy in the core provides an ideal reaction environment for the in-situ formation of the TiB2 nanophase, while the Al-Cu-Mg alloy in the shell provides solid solution strengthening elements for the matrix. This layered design not only achieves spatial separation of the reinforcing phase and solid solution strengthening elements, but also creates conditions for the synergistic effect of the two strengthening mechanisms.

[0091] Secondly, the introduction of triaxial electromagnetic field modulation technology provides a powerful tool for the precise control of molten pool behavior. By independently adjusting the magnetic field strength and frequency in the x, y, and z directions, multi-dimensional control of molten pool flow, heat transfer, and solidification behavior can be achieved. This not only contributes to the uniform distribution of the TiB2 nanophase but also promotes the full diffusion and solidification of Cu and Mg elements. More importantly, electromagnetic field-induced molten pool convection significantly improves gas removal efficiency and effectively reduces the porosity of the material.

[0092] From a materials science perspective, the method of this invention achieves a synergistic effect of nano-reinforcing phase and solid solution strengthening. The TiB2 nanophase not only directly provides particle reinforcement but also improves material strength by pinning dislocations and refining grains. Simultaneously, the uniformly distributed TiB2 nanophase provides preferential channels for the diffusion of Cu and Mg atoms, accelerating the formation of the solid solution. This synergistic effect at the microstructural level is difficult to achieve using traditional preparation methods.

[0093] From a chemical mechanism perspective, this invention fully utilizes the thermodynamic and kinetic properties of the Al-Ti-B system. In a high-temperature molten pool, Ti and B atoms form the TiB2 nanophase through complex diffusion and nucleation processes. The presence of an electromagnetic field not only affects the diffusion behavior of Ti and B atoms but may also influence the nucleation and growth process of TiB2 by altering the local electronic structure. Simultaneously, the solid solution process of Cu and Mg atoms in the Al matrix is ​​also regulated by the electromagnetic field, potentially forming more complex point defect structures, thereby enhancing the solid solution strengthening effect.

[0094] Another significant advantage of this invention lies in the adjustability and adaptability of its process. By precisely controlling the composition ratio of the bilayer filaments, electromagnetic field parameters, and post-processing, the material's properties can be customized to meet specific application requirements. This high degree of designability provides ample room for the development of a new generation of high-performance aluminum-based composite materials.

[0095] In summary, this invention, through innovative material design and process control, successfully solves several key problems in existing technologies, achieving the precise preparation of high-performance aluminum-based composite materials. This method not only significantly improves the mechanical properties and corrosion resistance of the material but also possesses good process adaptability and scalability. Therefore, this invention provides a highly promising new material preparation solution for aerospace, automotive, and electronic packaging industries, and is expected to drive technological innovation and upgrading in related industries. Detailed Implementation

[0096] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0097] Example 1

[0098] This embodiment provides a method for additive manufacturing high-performance aluminum-based composite materials using a double-layer composite filament and electromagnetic field modulation. The method includes the following steps:

[0099] (1) Preparation of double-layer composite filament

[0100] First, the core alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in a graphite crucible and heated to 700°C under argon protection to melt. Then, 3.0 wt% of titanium powder with a purity of 99.5% and 0.5 wt% of boron powder with a purity of 99.5% were added, and the mixture was stirred at 300 rpm for 30 minutes. This step aimed to promote the in-situ formation of the TiB2 nanophase, providing a reinforcing phase with high strength and high modulus for the material. The melt was then poured into a metal mold preheated to 200°C and cooled to room temperature.

[0101] Next, the shell alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in another graphite crucible and heated to 750°C under argon protection to melt. Then, 2.5 wt% copper granules with a purity of 99.9% and 1.0 wt% magnesium ingots with a purity of 99.9% were added sequentially, with a stirring speed of 400 rpm for 20 minutes. The addition of Cu and Mg was intended to achieve solid solution strengthening, improving the strength and hardness of the material. The melt was poured into a metal mold preheated to 250°C and cooled to room temperature.

[0102] Next, the core alloy and shell alloy are each machined into round bars with a diameter of 8 mm. The shell alloy round bars are then machined into hollow round tubes with an inner diameter slightly larger than that of the core alloy round bars. The core alloy round bars are inserted into the hollow shell alloy round tubes, ensuring a tight fit between the two. This core-shell structure design is beneficial for the uniform distribution of the TiB2 phase and the synergistic effect of Cu-Mg solid solution strengthening.

[0103] Then, the assembled double-layer structure was placed in a vacuum hot isostatic pressing (HIP) apparatus and held at 500°C and 100MPa for 2 hours to achieve metallurgical bonding of the two alloy layers. Finally, the HIP-treated double-layer composite material was subjected to multiple hot extrusions and cold stretching processes to obtain a double-layer composite wire with a diameter of 1.2mm.

[0104] (2) Using triaxial electromagnetic fields to control the additive manufacturing process

[0105] In this step, a 1000W fiber laser is first used as the heat source. A triaxial electromagnetic field generator is designed and installed, capable of independently generating magnetic field strengths in the x, y, and z directions. An additive manufacturing chamber with inert gas protection is prepared.

[0106] The process parameters were set as follows: laser power 800W, scanning speed 600mm / min, wire feed speed 1500mm / min, layer thickness 0.2mm, argon flow rate 15L / min, and substrate preheating temperature 150℃. The electromagnetic field parameters were set as follows: x-axis magnetic field strength 0.2T, y-axis magnetic field strength 0.3T, z-axis magnetic field strength 0.4T, and magnetic field frequency 10Hz. Precise control of these parameters aimed to optimize the molten pool behavior, promote the uniform distribution of the TiB2 nanophase, and achieve complete solid solution of Cu-Mg elements.

[0107] The manufacturing process is as follows: First, the double-layer composite filament is loaded into the filament feeding device. Second, the inert gas protection system is activated to fill the forming chamber with argon gas. Then, the substrate is preheated to the set temperature. Next, the triaxial electromagnetic field system is activated. Then, the laser scanning and filament feeding process begins, performing layer-by-layer deposition. After each layer is deposited, a 20-second cooling time is maintained. The above process is repeated until the entire part is manufactured.

[0108] (3) Post-processing of the obtained aluminum-based composite material

[0109] The manufactured parts are cooled to room temperature in an inert gas environment. They are then subjected to a T6 heat treatment, which includes: solution treatment (530°C, held for 1 hour), water quenching to room temperature, and aging treatment (160°C, held for 6 hours). This heat treatment process aims to further optimize the microstructure of the material and improve its strength and toughness.

[0110] Preferably, in embodiments of the present invention, after each layer is deposited during the additive manufacturing process, an eddy current flaw detector is used to perform real-time non-destructive testing on the deposited layer, with a testing frequency of 1MHz and a scanning speed of 50mm / s. This step helps to promptly detect and correct defects that may occur during the manufacturing process, improving the quality consistency of the final product.

[0111] Example 2

[0112] This embodiment provides a method for additive manufacturing high-performance aluminum-based composite materials using a double-layer composite filament and electromagnetic field modulation. The method includes the following steps:

[0113] (1) Preparation of double-layer composite filament

[0114] First, the core alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in a graphite crucible and heated to 725°C under argon protection to melt. Then, 4.5 wt% titanium powder with a purity of 99.5% and 1.0 wt% boron powder with a purity of 99.5% were added, and the mixture was stirred at 350 rpm for 45 minutes. This formulation aims to increase the volume fraction of the TiB2 nanophase, further improving the material's strength and wear resistance. The melt was then poured into a metal mold preheated to 225°C and cooled to room temperature.

[0115] Next, the shell alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in another graphite crucible and heated to 725°C under argon protection to melt. Then, 3.75 wt% copper granules with a purity of 99.9% and 1.75 wt% magnesium ingots with a purity of 99.9% were added sequentially, with the stirring speed at 350 rpm for 30 minutes. This ratio was designed to enhance the Cu-Mg solid solution strengthening effect while maintaining good plasticity. The melt was poured into a metal mold preheated to 225°C and cooled to room temperature.

[0116] Next, the core alloy and shell alloy are each machined into round bars with a diameter of 9 mm. The shell alloy round bars are then machined into hollow round tubes with an inner diameter slightly larger than that of the core alloy round bars. The core alloy round bars are then inserted into the hollow shell alloy round tubes, ensuring a tight fit between the two.

[0117] Then, the assembled double-layer structure was placed in a vacuum hot isostatic pressing (HIP) apparatus and held at 525°C and 125 MPa for 3 hours to achieve metallurgical bonding of the two alloy layers. Finally, the HIP-treated double-layer composite material was subjected to multiple hot extrusions and cold stretching processes to obtain a double-layer composite wire with a diameter of 1.4 mm.

[0118] (2) Using triaxial electromagnetic fields to control the additive manufacturing process

[0119] In this step, a 1250W fiber laser is first used as the heat source. A triaxial electromagnetic field generator is designed and installed, capable of independently generating magnetic field strengths in the x, y, and z directions. An additive manufacturing chamber with inert gas protection is prepared.

[0120] The process parameters were set as follows: laser power 1000W, scanning speed 800mm / min, wire feed speed 2000mm / min, layer thickness 0.3mm, argon flow rate 20L / min, and substrate preheating temperature 175℃. The electromagnetic field parameters were set as follows: x-axis magnetic field strength 0.25T, y-axis magnetic field strength 0.35T, z-axis magnetic field strength 0.45T, and magnetic field frequency 30Hz. These parameters were adjusted to optimize the molten pool dynamics and improve the dispersion uniformity of the TiB2 nanophase and the diffusion rate of Cu-Mg elements.

[0121] The manufacturing process is as follows: First, the double-layer composite filament is loaded into the filament feeding device. Second, the inert gas protection system is activated to fill the forming chamber with argon gas. Then, the substrate is preheated to the set temperature. Next, the triaxial electromagnetic field system is activated. Then, the laser scanning and filament feeding process begins, performing layer-by-layer deposition. After each layer is deposited, a 25-second cooling time is allowed. The above process is repeated until the entire part is manufactured.

[0122] (3) Post-processing of the obtained aluminum-based composite material

[0123] The manufactured parts were cooled to room temperature in an inert gas environment. They were then subjected to a T6 heat treatment, which included: solution treatment (540°C, 1.5 hours), water quenching to room temperature, and aging treatment (170°C, 7 hours). This heat treatment process aims to fully utilize the potential of Cu-Mg solid solution strengthening while maintaining the stability of the TiB2 nanophase.

[0124] Preferably, in embodiments of the present invention, the obtained aluminum-based composite material can also undergo surface treatment after T6 heat treatment. First, sandblasting is performed using 100-mesh alumina sand at a sandblasting pressure of 0.5 MPa. Second, anodizing is performed in a 20 wt% sulfuric acid solution at a current density of 1.5 A / dm³. 2 The temperature is 20℃, and the time is 45 minutes. Finally, a sealing treatment is performed by immersing in boiling water for 22 minutes. This series of surface treatments aims to improve the corrosion resistance and surface hardness of the material, expanding its application potential in harsh environments.

[0125] Example 3

[0126] This embodiment provides a third method for manufacturing high-performance aluminum-based composite materials using a double-layer composite filament and electromagnetic field-controlled additive manufacturing. The method includes the following steps:

[0127] (1) Preparation of double-layer composite filament

[0128] First, the core alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in a graphite crucible and heated to 750°C under argon protection to melt. Then, 6.0 wt% titanium powder with a purity of 99.5% and 1.5 wt% boron powder with a purity of 99.5% were added, and the mixture was stirred at 400 rpm for 60 minutes. This formulation and process parameters were designed to maximize the formation of the TiB2 nanophase, significantly improving the strength and stiffness of the material. The melt was then poured into a metal mold preheated to 250°C and cooled to room temperature.

[0129] Next, the shell alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in another graphite crucible and heated to 700°C under argon protection to melt. Then, 5.0 wt% copper granules with a purity of 99.9% and 2.5 wt% magnesium ingots with a purity of 99.9% were added sequentially, with the stirring speed at 300 rpm for 40 minutes. This formulation aims to achieve the strongest Cu-Mg solid solution strengthening effect while balancing strength and toughness by controlling the stirring speed and time. The melt was poured into a metal mold preheated to 200°C and cooled to room temperature.

[0130] Next, the core alloy and shell alloy are each machined into round bars with a diameter of 10 mm. The shell alloy round bars are then machined into hollow round tubes with an inner diameter slightly larger than that of the core alloy round bars. The core alloy round bars are then inserted into the hollow shell alloy round tubes, ensuring a tight fit between the two.

[0131] Then, the assembled bilayer structure was placed in a vacuum hot isostatic pressing (HIP) apparatus and held at 550°C and 150 MPa for 4 hours to achieve metallurgical bonding between the two alloy layers. These process parameters aim to ensure a stable metallurgical bond between the two alloy layers while avoiding excessive growth of the TiB2 nanophase. Finally, the HIP-treated bilayer composite material was subjected to multiple hot extrusions and cold stretching processes to obtain a bilayer composite filament with a diameter of 1.6 mm.

[0132] (2) Using triaxial electromagnetic fields to control the additive manufacturing process

[0133] In this step, a 1500W fiber laser is first used as the heat source. A triaxial electromagnetic field generator is designed and installed, capable of independently generating magnetic field strengths in the x, y, and z directions. An additive manufacturing chamber with inert gas protection is prepared.

[0134] The process parameters were set as follows: laser power 1200W, scanning speed 1000mm / min, wire feed speed 2500mm / min, layer thickness 0.4mm, argon flow rate 25L / min, and substrate preheating temperature 200℃. The electromagnetic field parameters were set as follows: x-axis magnetic field strength 0.3T, y-axis magnetic field strength 0.4T, z-axis magnetic field strength 0.5T, and magnetic field frequency 50Hz. These parameters were set to maximize the control effect of the electromagnetic field on the molten pool behavior, promote the uniform distribution of the TiB2 nanophase and the full diffusion of Cu-Mg elements, and refine the solidification structure through a high-frequency electromagnetic field.

[0135] The manufacturing process is as follows: First, the double-layer composite filament is loaded into the filament feeding device. Second, the inert gas protection system is activated to fill the forming chamber with argon gas. Then, the substrate is preheated to the set temperature. Next, the triaxial electromagnetic field system is activated. Then, the laser scanning and filament feeding process begins, performing layer-by-layer deposition. After each layer is deposited, a 30-second cooling time is allowed. The above process is repeated until the entire part is manufactured.

[0136] (3) Post-processing of the obtained aluminum-based composite material

[0137] The manufactured parts are cooled to room temperature in an inert gas environment. They are then subjected to a T6 heat treatment, which includes: solution treatment (550°C, held for 2 hours), water quenching to room temperature, and aging treatment (180°C, held for 8 hours). These heat treatment parameters are designed to fully dissolve Cu and Mg elements, forming a large number of strengthening phases, while achieving an optimal strength-toughness balance through prolonged aging.

[0138] Preferably, in embodiments of the present invention, a high-speed camera can be used to monitor the molten pool status in real time during the additive manufacturing process. The camera has a frame rate of 2000fps and a resolution of 1280x1024 pixels, and the laser power and wire feed speed are adjusted in real time based on image analysis results at a frequency of 20Hz. This real-time monitoring and feedback system can significantly improve the stability and controllability of the manufacturing process, further enhancing the consistency of the final product quality.

[0139] Example 4

[0140] This embodiment provides a fourth method for manufacturing high-performance aluminum-based composite materials using a double-layer composite filament and electromagnetic field-controlled additive manufacturing. The method includes the following steps:

[0141] (1) Preparation of double-layer composite filament

[0142] First, the core alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in a graphite crucible and heated to 725°C under argon protection to melt. Then, 4.5 wt% titanium powder with a purity of 99.5% and 1.0 wt% boron powder with a purity of 99.5% were added, and the mixture was stirred at 350 rpm for 45 minutes. This formulation and process parameters were designed to achieve the optimal size distribution (20-50 nm) of the TiB2 nanophase for the desired strengthening effect. The melt was then poured into a metal mold preheated to 225°C and cooled to room temperature.

[0143] Next, the shell alloy was prepared. Pure aluminum ingots with a purity of 99.99% were placed in another graphite crucible and heated to 725°C under argon protection to melt. Then, 3.75 wt% copper granules with a purity of 99.9% and 1.75 wt% magnesium ingots with a purity of 99.9% were added sequentially, with the stirring speed at 350 rpm for 30 minutes. This ratio was designed to achieve the optimal synergistic effect of Cu-Mg solid solution strengthening and TiB2 nanophase reinforcement. The melt was poured into a metal mold preheated to 225°C and cooled to room temperature.

[0144] Next, the core alloy and shell alloy are each machined into round bars with a diameter of 9 mm. The shell alloy round bars are then machined into hollow round tubes with an inner diameter slightly larger than that of the core alloy round bars. The core alloy round bars are then inserted into the hollow shell alloy round tubes, ensuring a tight fit between the two.

[0145] Then, the assembled bilayer structure was placed in a vacuum hot isostatic pressing (HIP) apparatus and held at 525°C and 125 MPa for 3 hours to achieve metallurgical bonding of the two alloy layers. These process parameters aim to ensure full bonding of the two alloy layers while avoiding excessive growth of the TiB2 nanophase and excessive diffusion of Cu-Mg elements. Finally, the HIP-treated bilayer composite material was subjected to multiple hot extrusions and cold stretching processes to ultimately produce a bilayer composite wire with a diameter of 1.4 mm.

[0146] (2) Using triaxial electromagnetic fields to control the additive manufacturing process

[0147] In this step, a 1250W fiber laser is first used as the heat source. A triaxial electromagnetic field generator is designed and installed, capable of independently generating magnetic field strengths in the x, y, and z directions. An additive manufacturing chamber with inert gas protection is prepared.

[0148] The process parameters were set as follows: laser power 1000W, scanning speed 800mm / min, wire feed speed 2000mm / min, layer thickness 0.3mm, argon flow rate 20L / min, and substrate preheating temperature 175℃. The electromagnetic field parameters were set as follows: x-axis magnetic field strength 0.25T, y-axis magnetic field strength 0.35T, z-axis magnetic field strength 0.45T, and magnetic field frequency 30Hz. These parameters were set to achieve optimal fluid flow within the molten pool, promote uniform distribution of the TiB2 nanophase and sufficient diffusion of Cu-Mg elements, and refine the solidification structure through electromagnetic stirring.

[0149] The manufacturing process is as follows: First, the double-layer composite filament is loaded into the filament feeding device. Second, the inert gas protection system is activated to fill the forming chamber with argon gas. Then, the substrate is preheated to the set temperature. Next, the triaxial electromagnetic field system is activated. Then, the laser scanning and filament feeding process begins, performing layer-by-layer deposition. After each layer is deposited, a 25-second cooling time is allowed. The above process is repeated until the entire part is manufactured.

[0150] (3) Post-processing of the obtained aluminum-based composite material

[0151] The manufactured parts were cooled to room temperature in an inert gas environment. They were then subjected to a T6 heat treatment, which included: solution treatment (540°C, 1.5 hours), water quenching to room temperature, and aging treatment (170°C, 7 hours). These heat treatment parameters were designed to achieve the optimal precipitation state of the Cu-Mg solid solution-strengthened phase while maintaining the stability of the TiB2 nanophase, thus obtaining the best balance between strength and toughness.

[0152] Preferably, in embodiments of the present invention, the following control measures may also be implemented during the additive manufacturing process:

[0153] a) In-situ TiB2 formation control: reaction temperature 725℃, reaction time 45 minutes, stirring speed 350 rpm, cooling rate 70℃ / s. Precise control of these parameters helps to obtain TiB2 nanophases of ideal size and distribution.

[0154] b) Cu-Mg solid solution strengthening control: The solid solution treatment temperature is 540℃, the solid solution time is 1.5 hours, the quenching medium is water at 22℃, the aging temperature is 170℃, and the aging time is 7 hours. This process aims to achieve the best solid solution strengthening effect of Cu-Mg elements.

[0155] c) Electromagnetic field control: The magnetic field strength ranges from 0.25 to 0.45 T, the magnetic field frequency is 30 Hz, and the magnetic field direction is independently controlled along the x, y, and z axes. The magnetic field waveform is a sine wave. This electromagnetic field configuration can effectively control the behavior of the molten pool, promote gas expulsion, and refine the microstructure.

[0156] d) Porosity control: Inert gas purity 99.999%, gas flow rate 20 L / min, molding chamber pressure 1.15 standard atmospheres, melt pool temperature 690℃. Precise control of these parameters helps to reduce porosity to below 0.3%, significantly improving the mechanical properties and service life of the material.

[0157] Comparative Example 1: Single-layer aluminum alloy wire and its conventional additive manufacturing method

[0158] This comparative example aims to verify the superiority of the double-layer composite filament structure and is compared with Example 1. The method includes the following steps:

[0159] (1) Preparation of single-layer aluminum alloy wire

[0160] First, 99.99% pure aluminum ingots were placed in a graphite crucible and heated to 725°C under argon protection to melt them. Then, 3.0 wt% of 99.5% pure titanium powder, 0.5 wt% of 99.5% pure boron powder, 2.5 wt% of 99.9% pure copper granules, and 1.0 wt% of 99.9% pure magnesium ingots were added, and the mixture was stirred at 350 rpm for 40 minutes. This step aims to mix the core and shell alloy components together to verify the necessity of a double-layer structure.

[0161] The melt is then poured into a metal mold preheated to 225°C and cooled to room temperature. Next, the alloy is machined into round bars with a diameter of 9 mm, and through multiple hot extrusions and cold stretchings, a single-layer alloy wire with a diameter of 1.2 mm is finally obtained.

[0162] (2) Conventional additive manufacturing process

[0163] In this step, a 1000W fiber laser is used as the heat source, but electromagnetic field control is not employed. The process parameters are set the same as in Example 1, but without the electromagnetic field-related parameters.

[0164] The manufacturing process is as follows: First, a single-layer alloy wire is loaded into the wire feeding device. Second, the inert gas protection system is activated to fill the forming chamber with argon gas. Then, the substrate is preheated to the set temperature. Next, the laser scanning and wire feeding process begins, performing layer-by-layer deposition. After each layer is deposited, a 20-second cooling time is maintained. The above process is repeated until the entire part is manufactured.

[0165] (3) Post-processing

[0166] The post-processing steps are the same as in Example 1.

[0167] A comparison with Example 1 reveals that the single-layer alloy wire cannot achieve localized distribution of the TiB2 phase and gradient distribution of Cu-Mg elements, resulting in a less significant reinforcing effect compared to the bilayer structure. Furthermore, the lack of electromagnetic field control makes precise control of the molten pool behavior difficult, potentially leading to increased porosity and uneven microstructure.

[0168] Comparative Example 2: Bilayer Composite Wire and its Uniaxial Electromagnetic Field-Controlled Additive Manufacturing Method

[0169] This comparative example aims to verify the necessity of triaxial electromagnetic field manipulation and is compared with Example 2. The method includes the following steps:

[0170] (1) Preparation of double-layer composite filament

[0171] The preparation method of the double-layer composite filament is exactly the same as that in Example 2.

[0172] (2) Monoaxial electromagnetic field controlled additive manufacturing process

[0173] In this step, a 1250W fiber laser is used as the heat source, but only single-axis (z-axis) electromagnetic field control is employed. The process parameters are set the same as in Example 2, but the electromagnetic field parameters are limited to a z-axis magnetic field strength of 0.45T and a magnetic field frequency of 30Hz.

[0174] The manufacturing process is similar to that of Example 2, but only the z-axis electromagnetic field system is activated.

[0175] (3) Post-processing

[0176] The post-processing steps are the same as in Example 2.

[0177] By comparing with Example 2, it can be observed that uniaxial electromagnetic field manipulation cannot achieve precise control over the three-dimensional flow of the molten pool, resulting in reduced uniformity of the TiB2 nanophase distribution and less efficient diffusion of Cu-Mg elements compared to triaxial electromagnetic field manipulation. This comparison highlights the important role of triaxial electromagnetic fields in optimizing the microstructure of materials.

[0178] Comparative Example 3: Bilayer Composite Wire and its High-Power Laser Additive Manufacturing Method

[0179] This comparative example aims to verify the importance of appropriate laser power and electromagnetic field strength, and is compared with Example 3. The method includes the following steps:

[0180] (1) Preparation of double-layer composite filament

[0181] The preparation method of the double-layer composite filament is exactly the same as that in Example 3.

[0182] (2) High-power laser additive manufacturing process

[0183] In this step, a 2000W fiber laser was used as the heat source, significantly increasing the laser power. The process parameters were set as follows: laser power 1800W, scanning speed 1200mm / min, wire feed speed 3000mm / min, and other parameters were the same as in Example 3. The electromagnetic field parameters were set as follows: x-axis magnetic field strength 0.4T, y-axis magnetic field strength 0.5T, z-axis magnetic field strength 0.6T, and magnetic field frequency 70Hz.

[0184] The manufacturing process is similar to that of Example 3, but uses higher laser power and electromagnetic field strength.

[0185] (3) Post-processing

[0186] The post-processing steps are the same as in Example 3.

[0187] A comparison with Example 3 reveals that excessively high laser power and electromagnetic field strength can lead to excessively high molten pool temperatures, causing TiB2 nanophase growth and reducing its strengthening effect. Simultaneously, an excessively strong electromagnetic field can cause overly vigorous molten pool flow, affecting the formation of the solidified structure. This comparison highlights the importance of precisely controlling process parameters in this invention.

[0188] Comparative Example 4: Bilayer Composite Wire and its Inert Gas-Free Additive Manufacturing Method

[0189] This comparative example aims to verify the necessity of inert gas protection and is compared with Example 4. The method includes the following steps:

[0190] (1) Preparation of double-layer composite filament

[0191] The preparation method of the double-layer composite filament is exactly the same as that in Example 4.

[0192] (2) Additive manufacturing process without inert gas protection

[0193] In this step, the process parameters are set the same as in Example 4, but inert gas protection is not used. The manufacturing process is carried out in air, and the other steps are similar to those in Example 4.

[0194] (3) Post-processing

[0195] The post-processing steps are the same as in Example 4.

[0196] A comparison with Example 4 reveals that the lack of inert gas protection leads to severe oxidation of the material at high temperatures, resulting in numerous oxide inclusions and a significant reduction in its mechanical properties. Furthermore, the oxidation reaction interferes with the in-situ formation of TiB2 and the solid solution process of Cu-Mg, affecting the strengthening effect of the material. This comparison highlights the crucial role of inert gas protection in ensuring material quality.

[0197] Comparative Example 5: Bilayer Composite Wire and its Additive Manufacturing Method Without Post-processing

[0198] This comparative example aims to verify the importance of post-treatment (especially T6 heat treatment) and is compared with Example 1. The method includes the following steps:

[0199] (1) Preparation of double-layer composite filament

[0200] The preparation method of the double-layer composite filament is exactly the same as that in Example 1.

[0201] (2) Electromagnetic field controlled additive manufacturing process

[0202] The additive manufacturing process is exactly the same as in Example 1.

[0203] (3) No post-processing

[0204] This comparative example omits all post-processing steps, including the T6 heat treatment.

[0205] A comparison with Example 1 reveals that the absence of T6 heat treatment significantly reduces the Cu-Mg solid solution strengthening effect, resulting in material strength and hardness that are significantly lower than the heat-treated sample. Furthermore, the untreated sample may exhibit higher residual stress, affecting material stability and service life. This comparison highlights the crucial role of post-treatment in optimizing material properties.

[0206] Comparative Example 6: High Ti, B content bilayer composite filament and its electromagnetic field-controlled additive manufacturing method

[0207] This comparative example aims to verify the importance of appropriate Ti and B contents for the formation of the TiB2 nanophase, and is compared with Example 2. The method includes the following steps:

[0208] (1) Preparation of high Ti and B content double-layer composite filament

[0209] The preparation method of the core alloy is similar to that of Example 2, but the contents of Ti and B are increased to 8.0 wt% and 2.0 wt%, respectively. The preparation method of the shell alloy is exactly the same as that of Example 2.

[0210] (2) Electromagnetic field controlled additive manufacturing process

[0211] The additive manufacturing process is exactly the same as in Example 2.

[0212] (3) Post-processing

[0213] The post-processing steps are the same as in Example 2.

[0214] A comparison with Example 2 reveals that while excessively high Ti and B contents increase the volume fraction of the TiB2 phase, they also lead to coarsening of the TiB2 particles, with sizes exceeding the ideal 20-50 nm range. This not only reduces the strengthening effect of TiB2 but may also cause a decrease in the material's toughness. Furthermore, excessive TiB2 phase affects the diffusion and solid solution process of Cu-Mg elements, reducing the effectiveness of solid solution strengthening. This comparison highlights the importance of precisely controlling the alloy composition in this invention to achieve the optimal synergistic effect of TiB2 nanophase and Cu-Mg solid solution strengthening.

[0215] These six comparative examples comprehensively verify the importance of key innovations in this invention, including the double-layer composite wire structure, triaxial electromagnetic field control, reasonable process parameters, inert gas protection, post-treatment, and appropriate alloy composition. These comparative results strongly support the inventiveness and superiority of this invention, providing important scientific basis and technical guidance for the development of high-performance aluminum-based composite materials.

[0216] To comprehensively evaluate the effectiveness and superiority of this invention, a series of test experiments were designed. Experimental design and methods:

[0217] 1. Microstructure analysis

[0218] First, the microstructure of the samples was analyzed using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). SEM observation was performed using a FEIQuanta 450FEG with an accelerating voltage of 20 kV. TEM observation was performed using a JEOL JEM-2100F with an accelerating voltage of 200 kV. Sample preparation was performed using a precision ion milling system (PIPS). This analysis aimed to observe the size and distribution of the TiB2 nanophase and the solid solution of Cu and Mg elements.

[0219] 2. Mechanical property testing

[0220] Secondly, tensile and hardness tests were conducted. Tensile tests were performed using an Instron 5967 universal testing machine at a tensile rate of 2 mm / min. Hardness tests were performed using a Vickers hardness tester with a load of 500 g and a holding time of 15 s. These tests aimed to evaluate the material's strength, ductility, and hardness.

[0221] 3. Simulation of electromagnetic field distribution

[0222] Then, the distribution of the triaxial electromagnetic field in the molten pool was numerically simulated using COMSOL Multiphysics software. The simulation parameters were based on actual process conditions, including the molten pool geometry, material conductivity, and magnetic permeability. This simulation helps to understand the mechanism by which the electromagnetic field affects the molten pool flow.

[0223] 4. Residual stress analysis

[0224] Next, the residual stress of the samples was measured using X-ray diffraction (XRD). A Bruker D8 Advance diffractometer with a Cu Kα radiation source was used, operating at 40 kV and 40 mA. The stress was calculated using the sin²ψ method. This analysis aims to assess the effect of electromagnetic field modulation on the residual stress.

[0225] 5. Corrosion resistance test

[0226] Finally, electrochemical corrosion tests were performed using a CHI660E electrochemical workstation in a 3.5 wt% NaCl solution. A three-electrode system was employed, with a saturated calomel electrode (SCE) as the reference electrode and a platinum electrode as the counter electrode. This test aimed to evaluate the corrosion resistance of the material.

[0227] Test results:

[0228] Table 1. Test results of microstructure and mechanical properties

[0229]

[0230] Table 2. Results of Residual Stress and Corrosion Resistance Tests

[0231]

[0232]

[0233] Based on the above test results, the following conclusions can be drawn:

[0234] 1. The preferred embodiment is Example 3, which exhibits the best performance in terms of strength, hardness, and corrosion resistance. This is mainly due to its optimal TiB2 nanophase size (25 nm) and distribution, as well as the sufficient solid solution of Cu-Mg elements.

[0235] 2. The double-layer composite filament structure of the present invention (Examples 1-4) has significantly improved performance in all aspects compared with the single-layer structure (Comparative Example 1), which confirms the superiority of the double-layer structure.

[0236] 3. Triaxial electromagnetic field modulation (Examples 1-4) can more effectively control the size and distribution of TiB2 nanophase compared to uniaxial electromagnetic field (Comparative Example 2) or no electromagnetic field (Comparative Example 1), thereby obtaining better mechanical properties and corrosion resistance.

[0237] 4. Appropriate laser power and electromagnetic field strength (Examples 1-4) can better balance strength and toughness compared to excessively high parameters (Comparative Example 3).

[0238] 5. Inert gas protection (Examples 1-4) compared to no protection (Comparative Example 4) can significantly improve the mechanical properties and corrosion resistance of materials.

[0239] 6. Post-treatment, especially T6 heat treatment (Examples 1-4), can fully utilize the Cu-Mg solid solution strengthening effect and improve the overall performance of the material compared with no post-treatment (Comparative Example 5).

[0240] 7. Reasonable control of Ti and B content (Examples 1-4) can obtain a more ideal TiB2 nanophase size and distribution compared with excessively high content (Comparative Example 6), thereby achieving a better strength-toughness balance.

[0241] A thorough analysis of these results reveals that the present invention has the following unexpected technical effects:

[0242] 1. Synergistic Strengthening Effect: A significant synergistic effect exists between the TiB2 nanophase and Cu-Mg solid solution strengthening. The TiB2 nanophase not only plays a direct strengthening role but also promotes the uniform distribution of Cu-Mg elements, enhancing the solid solution strengthening effect. This synergistic effect makes the strength improvement of the material go beyond the simple superposition of individual strengthening mechanisms.

[0243] 2. Adaptive Microstructure: Triaxial electromagnetic field modulation creates a dynamic molten pool environment, enabling the TiB2 nanophase and Cu-Mg elements to adaptively distribute according to local cooling conditions. This adaptability significantly improves the material's uniformity and performance stability.

[0244] 3. Residual stress control: Electromagnetic field modulation not only affects the microstructure but also significantly reduces the residual stress of the material. This effect may stem from the fact that electromagnetic field-induced molten pool convection promotes uniform heat distribution and reduces local thermal gradients.

[0245] 4. Enhanced Corrosion Resistance: The uniform distribution of the TiB2 nanophase and the solid solution of Cu-Mg elements not only improve the mechanical properties of the material but also significantly enhance its corrosion resistance. This may be due to the formation of a dense protective film on the material surface by the TiB2 nanophase, while the Cu-Mg solid solution alters the electrochemical properties of the material.

[0246] 5. Expanded Process Window: By precisely controlling multiple process parameters, the method of this invention significantly expands the preparation process window for high-performance aluminum-based composite materials. This means that the method has higher tolerance and adaptability, which is beneficial for industrial production.

[0247] 6. Microstructure Designability: By adjusting the composition, electromagnetic field parameters, and post-processing techniques of the bilayer filaments, the microstructure of the material can be precisely designed. This designability provides a new approach for developing customized materials with specific properties.

[0248] In summary, this invention achieves a synergistic effect of TiB2 nanophase reinforcement and Cu-Mg solid solution strengthening through innovative double-layer composite filament design and triaxial electromagnetic field modulation, while also providing a new method for precisely controlling the microstructure of materials. This not only significantly improves the overall performance of aluminum-based composite materials but also provides an important technological foundation for the development of next-generation high-performance lightweight materials.

[0249] The above description is merely an embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of the present invention should be included within the scope of the claims of the present invention.

Claims

1. A method for additive manufacturing high-performance aluminum-based composite materials using a double-layer composite filament and electromagnetic field modulation thereof, characterized in that, Includes the following steps: (1) Preparation of double-layer composite filament; (2) Using triaxial electromagnetic fields to control the additive manufacturing process; (3) Post-processing of the obtained aluminum-based composite material; The method for preparing the double-layer composite filament in step (1) includes: (a) Preparing the core alloy, including the following steps: First, pure aluminum ingots with a purity of ≥99.99% are placed in a graphite crucible and heated to 700-750℃ under argon protection to melt them; Next, add the predetermined amount of titanium powder with a purity ≥99.5% and boron powder with a purity ≥99.5%, stir at 300-400 rpm, and keep for 30-60 minutes; Then, the melt is poured into a metal mold preheated to 200-250°C and cooled to room temperature; (b) Preparing the shell alloy, including the following steps: First, place pure aluminum ingots with a purity of ≥99.99% in another graphite crucible and heat them to 700-750℃ under argon protection to melt them; Next, add the predetermined amounts of copper granules with a purity ≥99.9% and magnesium ingots with a purity ≥99.9% in sequence, and stir at 300-400 rpm for 20-40 minutes. Then, the melt is poured into a metal mold preheated to 200-250°C and cooled to room temperature; (c) The core alloy and the shell alloy are respectively machined into round bars with a diameter of 8-10 mm; (d) The shell alloy round bar is machined into a hollow round tube with an inner diameter slightly larger than that of the core alloy round bar; (e) Insert the core alloy round bar into the shell alloy hollow round tube to ensure that the two fit tightly together; (f) Place the assembled double-layer structure in a vacuum hot isostatic pressing equipment and maintain it at 500-550℃ and 100-150MPa for 2-4 hours. (g) The double-layer composite material after hot isostatic pressing is subjected to multiple hot extrusions and cold stretchings to finally obtain a double-layer composite filament with a diameter of 1.2-1.6 mm. The composition of the core alloy is as follows: Aluminum: 92.5-96.0% by weight Titanium: 3.0-6.0% by weight Boron: 0.5-1.5% by weight The composition of the shell alloy is as follows: Aluminum: 93.0-96.5% by weight Copper: 2.5-5.0% by weight Magnesium: 1.0-2.5% by weight; The step (2) of controlling the additive manufacturing process using a triaxial electromagnetic field includes the following steps: (a) Equipment preparation: A fiber laser with a power of 1000-1500W is used as the heat source; Design and install a triaxial electromagnetic field generator capable of independently generating magnetic field strengths of 0.2-0.5T in the x, y, and z directions; Prepare an additive manufacturing chamber with inert gas protection. (b) Process parameter settings: Laser power: 800-1200W; Scanning speed: 600-1000 mm / min; Wire feeding speed: 1500-2500 mm / min; Layer thickness: 0.2-0.4mm; Argon flow rate: 15-25 L / min; Substrate preheating temperature: 150-200℃; (c) Electromagnetic field parameter settings: x-axis magnetic field strength: 0.2-0.3T; y-axis magnetic field strength: 0.3-0.4T; z-axis magnetic field strength: 0.4-0.5T; Magnetic field frequency: 10-50Hz; (d) Manufacturing process: First, load the double-layer composite filament into the filament feeding device; Secondly, the inert gas protection system is activated to fill the molding chamber with argon gas; Then, preheat the substrate to the set temperature; Next, start the triaxial electromagnetic field system; Next, the laser scanning and wire feeding process begins, and layer-by-layer deposition is carried out; After each layer is deposited, allow it to cool for 20-30 seconds. Repeat the above process until the entire part is manufactured.

2. The method according to claim 1, characterized in that, The post-processing in step (3) includes the following steps: (a) Cool the manufactured parts to room temperature in an inert gas environment; (b) Perform T6 heat treatment, including: Solution treatment: 530-550℃, hold for 1-2 hours; Quenching: Water quenching to room temperature; Aging treatment: 160-180℃, keep for 6-8 hours.

3. The method according to claim 2, characterized in that, The method also includes the following control points: (a) In-situ generation control of TiB2: Reaction temperature: 700-750℃; Reaction time: 30-60 minutes; Stirring speed: 300-400 rpm; Cooling rate: >50℃ / s; (b) Cu-Mg solid solution strengthening control: Solution treatment temperature: 530-550℃; Solution treatment time: 1-2 hours; Quenching medium: water, temperature: 20-25℃; Aging temperature: 160-180℃; Delivery time: 6-8 hours; (c) Electromagnetic field manipulation: Magnetic field strength range: 0.2-0.5T; Magnetic field frequency: 10-50Hz; Magnetic field direction: independently controlled along the x, y, and z axes; Magnetic field waveform: sine wave; (d) Porosity control: Inert gas purity: ≥99.999%; Gas flow rate: 15-25 L / min; Molding chamber pressure: 1.1-1.2 standard atmospheres; Melt pool temperature: 660-720℃.

4. The method according to claim 3, characterized in that, The method further includes the following steps: In the additive manufacturing process, after each layer is deposited, an eddy current flaw detector is used to perform real-time non-destructive testing on the deposited layer. The testing frequency is 1-5MHz and the scanning speed is 50-100mm / s.

5. The method according to claim 4, characterized in that, The method further includes the following steps: After T6 heat treatment, the resulting aluminum-based composite material undergoes surface treatment, including: First, sandblasting is performed using alumina sand with a particle size of 80-120 mesh and a sandblasting pressure of 0.4-0.6 MPa. Secondly, anodizing treatment is carried out in a 20wt% sulfuric acid solution with a current density of 1-2 A / dm², a temperature of 18-22℃, and a time of 30-60 minutes. Finally, seal the holes by soaking them in boiling water for 15-30 minutes.

6. The method according to any one of claims 1-5, characterized in that, The method further includes the following steps: During the additive manufacturing process, a high-speed camera is used to monitor the state of the molten pool in real time. The camera has a frame rate of 1000-2000fps and a resolution of no less than 1280x1024 pixels. Based on the image analysis results, the laser power and wire feeding speed are adjusted in real time at a frequency of 10-20Hz.

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