Main wire swing three-wire composite electric arc additive manufacturing device and method

Abstract

The invention discloses a main wire swing three-wire composite electric arc additive manufacturing device and method and belongs to the field of electric arc welding / additive manufacturing, and the device comprises a consumable electrode gas shielded welding power source I, a consumable electrode gas shielded welding power source II, a main wire welding gun, an auxiliary wire welding gun I, an auxiliary wire welding gun II, a base plate, a welding gun clamp, a swing device and the like. An electrode of the consumable electrode gas shielded welding power source I is connected to the base plate and the main wire welding gun, and an electrode of the consumable electrode gas shielded welding power source II is connected to the auxiliary wire welding gun I and the auxiliary wire welding gun II. And a swinging device is additionally arranged on the main wire welding gun, so that the two electric arcs form a composite electric arc for welding / material adding. Metal elements in a welding seam are distributed more uniformly through main wire arc swinging, molten pool stirring and molten pool flowing behavior changing, heat transfer of base metal on the two sides of a welding bead can be accelerated, a wide welding bead and a large fusion depth are obtained at a time, the welding / additive material quality is improved, three wires are jointly melted and deposited, and the welding / additive material efficiency can be remarkably improved.

Description

Technical Field

[0001] The present invention specifically relates to a main-wire swinging three-wire composite arc additive manufacturing device and method, belonging to the field of arc welding / additive manufacturing. Background Art

[0002] Additive manufacturing technology is an emerging manufacturing technology that uses digital models to accumulate materials layer by layer to produce physical parts. Compared with traditional material removal techniques, it is a "bottom-up" material accumulation manufacturing method. Among them, arc additive manufacturing technology uses welding arc as a heat source to melt metal wire, and accumulates each layer on the substrate according to the set forming path, layer by layer until the metal part is formed. Traditional arc additive manufacturing technology causes instability in the molten pool due to the large heat input of the arc, resulting in large residual stress during the cladding process. Large residual stress will cause cracks and deformation in the components, affecting the quality of the components. At the same time, large heat input will produce spatter. Therefore, how to reduce the impact of the arc's heat input on the molten pool, reduce residual stress, improve welding quality and reduce spatter on the substrate is a key issue in the field of arc additive manufacturing.

[0003] The existing multi-wire arc additive technology uses the post-gas system to provide a special post-gas flow to change the original arc space airflow field state and the force mechanism of the liquid molten pool. Although the flow behavior of the molten pool can be regulated, the space airflow field will be unstable and the force of the molten pool will sometimes be uncontrolled, which will also affect the quality of the formed parts.

[0004] Therefore, there is an urgent need to develop a new device to stably regulate the molten pool behavior, reduce the residual stress during welding / additive manufacturing, improve the welding / additive manufacturing quality, and reduce the spatter generated during welding / additive manufacturing. Summary of the invention

[0005] In view of the problems existing in the prior art, the present invention provides a main-wire swinging three-wire composite arc additive manufacturing device and method, which utilizes a composite arc formed by a wire-plate arc and an arc between wires to melt the wire, and an swinging device causes the main wire to swing to generate a swinging arc. The swinging arc helps to stir the molten pool, improve the fluidity of the molten pool, and accelerate the heat transfer of the parent material on both sides of the weld, so as to obtain a faster weld and a deeper penetration at one time, so that the heat generated in welding / additive manufacturing is more evenly distributed in the thickness direction, and at the same time, the distribution of residual stress can be changed, thereby changing the forming defects of the workpiece.

[0006] The technical solution of the present invention is as follows: A main-wire swinging three-wire composite arc additive manufacturing device comprises a consumable electrode gas shielded welding power source I, a consumable electrode gas shielded welding power source II, a main-wire welding gun, an auxiliary-wire welding gun I, an auxiliary-wire welding gun II, a welding gun fixture, a wire feeding mechanism, a swinging device, a base plate, and a controller.

[0007] One electrode of the gas shielded welding power source I is connected to the main wire welding gun, and the other electrode is connected to the base plate. The output end of the gas shielded welding power source I is connected to a relay, and the conversion between the positive and negative poles is realized by the relay switch. One electrode of the gas shielded welding power source II is connected to the auxiliary wire welding gun I, and the other electrode is connected to the auxiliary wire welding gun II. The output end of the gas shielded welding power source II is connected to a relay, and the conversion between the positive and negative poles is realized by the relay switch.

[0008] The welding gun clamp is equipped with three sets of angle adjustment mechanisms and welding gun clamping mechanisms, and the angles among the main wire welding gun, the auxiliary wire welding gun I and the auxiliary wire welding gun II can be adjusted through the welding gun clamp.

[0009] The swing device is located in the main wire welding gun and is used for swinging the welding wire in the main wire welding gun.

[0010] According to the main wire swinging three-wire composite arc additive manufacturing device according to claim 1, the type of the metal electrode gas shielded welding power supply I and the metal electrode gas shielded welding power supply II is a direct current or alternating current power supply.

[0011] According to the main wire swinging three-wire composite arc additive manufacturing device according to claim 1, the welding gun clamping mechanism is responsible for clamping the welding gun, and the angle adjustment mechanism can adjust the angle between the welding gun and the horizontal plane within a range of 0-90°, the welding gun can be parallel to the horizontal plane, the distance between the welding gun in the horizontal direction can be adjusted, and the height of the welding gun from the substrate can also be adjusted.

[0012] According to the main wire swinging three-wire composite arc additive manufacturing device according to claim 1, the swinging device causes the main wire to swing according to different trajectories, frequencies and amplitudes, so that the composite arc swings at a certain frequency in the width direction of the weld.

[0013] According to the main-wire swinging three-wire composite arc additive manufacturing device described in claim 1, the controller can control the swinging device to swing in the form of any trajectory, and can also control the frequency and amplitude of the swing.

[0014] According to the main wire swinging three-wire composite arc additive manufacturing device described in claim 1, it is characterized in that the welding wires in the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II can be either the same wire material or different wire materials.

[0015] The present invention also provides a main wire swing three-wire composite arc additive manufacturing method, which adopts the main wire swing three-wire composite arc additive manufacturing device mentioned above, and specifically comprises the following steps: Pre-treat the substrate and place it in the position to be welded.

[0016] Extend the welding wires on the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II out of the welding gun by 0-25mm.

[0017] The welding gun angle is adjusted by the welding gun adjustment mechanism so that the welding wires on the main wire welding gun, auxiliary wire welding gun I and auxiliary wire welding gun II intersect at one point.

[0018] Adjust the welding gun fixture so that the intersection of the welding wire is 0-20 mm higher than the substrate. The working parameters are not limited to the above range.

[0019] Start the controller, which controls the current of the two consumable electrode gas shielded welding power sources, the wire feeding speed, the substrate moving speed, the main wire swing form, the switch of the relay and other system operations.

[0020] Start the consumable electrode gas shielded welding power supply I and the consumable electrode gas shielded welding power supply II at the same time, form a current loop between the main wire welding gun and the base plate to generate a wire-to-plate arc, form a current loop between the auxiliary wire welding gun I and the auxiliary wire welding gun II to generate an inter-wire arc, and the wire-to-plate arc and the inter-wire arc are coupled to form a composite arc.

[0021] The controller controls the swing device to swing along a certain trajectory, frequency and amplitude. The swing device drives the main wire welding gun to swing, so that the composite arc formed by the wire-plate arc and the arc between wires swings at a certain frequency in the direction of the weld width. The composite swinging arc melts the welding wire to form molten droplets, which fall off and transition into the molten pool. As the substrate moves, a welding / additive process is completed. The swinging arc helps to stir the molten pool, improve the fluidity of the molten pool, and accelerate the heat transfer of the parent material on both sides of the weld, so as to obtain a faster weld and a deeper penetration at one time, so that the heat generated in the additive is more evenly distributed in the thickness direction, and at the same time, the distribution of residual stress can be changed to change the forming defects of the workpiece.

[0022] After welding is completed, turn off the metal-metal gas shielded welding power supply I and metal-metal gas shielded welding power supply II in sequence, and turn off the controller.

[0023] Compared with the prior art, the present invention has the following advantages: the composite arc formed by the wire plate arc and the arc between the wires is used to melt the wires, the composite arc has greater heat, and can melt three wires at the same time, the controller controls the swing device to swing the main wire to generate a swinging arc, the swinging arc improves the shape of the arc, helps to stir the molten pool, improves the fluidity of the molten pool, accelerates the heat transfer of the parent material on both sides of the weld, obtains a faster weld and a deeper penetration at one time, makes the heat generated in the additive more evenly distributed in the thickness direction, solves the problem of large residual stress and poor surface forming of the workpiece during the additive process, changes the forming defects of the workpiece, and improves the welding quality. In addition, the device of the present invention has a simple structure and is easy to operate. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0025] In the figure: 1. Metal-metal arc welding power source I; 2. Metal-metal arc welding power source II; 3. Main wire welding gun; 4. Auxiliary wire welding gun I; 5. Auxiliary wire welding gun II; 6. Wire feeder; 7. Swing device; 8. Welding gun fixture; 9. Controller; 10. Base plate Figure 1 This is a schematic diagram of the structure of the main wire swinging three-wire composite arc additive manufacturing device of the present invention. Figure 2 Schematic diagram of the substrate welding / additive manufacturing process described in the present invention. DETAILED DESCRIPTION

[0026] like Figure 1 As shown, the present invention provides a main wire swinging three-wire composite arc additive manufacturing device, including a consumable electrode gas shielded welding power source I, a consumable electrode gas shielded welding power source II, a main wire welding gun, an auxiliary wire welding gun I, an auxiliary wire welding gun II, a welding gun clamp, a wire feeding mechanism, a swinging device, a base plate, and a controller.

[0027] One electrode of the gas shielded welding power source I is connected to the main wire welding gun, and the other electrode is connected to the base plate. The output end of the gas shielded welding power source I is connected to a double-pole double-throw relay, and the conversion between the positive and negative poles is achieved by switching the states of the two knives of the relay. One electrode of the gas shielded welding power source II is connected to the auxiliary wire welding gun I, and the other electrode is connected to the auxiliary wire welding gun II. The output end of the gas shielded welding power source II is connected to a double-pole double-throw relay, and the conversion between the positive and negative poles is achieved by switching the states of the two knives of the relay.

[0028] The welding gun clamp is equipped with three sets of angle adjustment mechanisms and welding gun clamping mechanisms, and the angles among the main wire welding gun, the auxiliary wire welding gun I and the auxiliary wire welding gun II can be adjusted through the welding gun clamp.

[0029] The swing device is located on the main wire welding gun and is used for swinging the welding wire in the main wire welding gun.

[0030] According to the main wire swinging three-wire composite arc additive manufacturing device according to claim 1, the type of the metal electrode gas shielded welding power supply I and the metal electrode gas shielded welding power supply II is a direct current or alternating current power supply.

[0031] According to the main wire swinging three-wire composite arc additive manufacturing device according to claim 1, the welding gun clamping mechanism is responsible for clamping the welding gun, and the angle adjustment mechanism can adjust the angle between the welding gun and the horizontal plane within a range of 0-90°, the welding gun can be parallel to the horizontal plane, the distance between the welding gun in the horizontal direction can be adjusted, and the height of the welding gun from the substrate can also be adjusted.

[0032] According to the main wire swinging three-wire composite arc additive manufacturing device according to claim 1, the swinging device causes the main wire to swing according to different trajectories, frequencies and amplitudes, so that the composite arc swings in the width direction of the weld.

[0033] According to the main-wire swinging three-wire composite arc additive manufacturing device described in claim 1, the controller can control the swinging device to swing in the form of any trajectory, and can also control the frequency and amplitude of the swing.

[0034] According to the main wire swinging three-wire composite arc additive manufacturing device described in claim 1, it is characterized in that the welding wires in the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II can be either the same wire material or different wire materials.

[0035] The present invention also provides a main wire swing three-wire composite arc additive manufacturing method, which adopts the main wire swing three-wire composite arc additive manufacturing device mentioned above, and specifically comprises the following steps: Pre-treat the substrate and place it in the position to be welded.

[0036] Extend the welding wires on the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II out of the welding gun by 0-25mm.

[0037] The welding gun angle is adjusted by the welding gun adjuster so that the initial positions of the welding wires on the main wire welding gun, auxiliary wire welding gun I and auxiliary wire welding gun II intersect at one point.

[0038] Adjust the welding gun fixture so that the intersection of the welding wire is 0-20 mm higher than the substrate. The working parameters are not limited to the above range.

[0039] Start the controller, which controls the current of the two gas shielded welding power supplies, the wire feeding speed, the substrate moving speed, the main wire swing form, the relay switch and other system operations.

[0040] Start the consumable electrode gas shielded welding power supply I and the consumable electrode gas shielded welding power supply II at the same time, form a current loop between the main wire welding gun and the base plate to generate a wire-to-plate arc, form a current loop between the auxiliary wire welding gun I and the auxiliary wire welding gun II to generate an inter-wire arc, and the wire-to-plate arc and the inter-wire arc are coupled to form a composite arc.

[0041] The controller controls the swing device to swing along a certain trajectory, frequency and amplitude. The swing device drives the main wire welding gun to swing, so that the composite arc formed by the wire-plate arc and the arc between wires swings at a certain frequency in the direction of the weld width. The composite swinging arc melts the welding wire to form molten droplets, which fall off and transition into the molten pool. As the substrate moves, a welding / additive process is completed. The swinging arc helps to stir the molten pool, improve the fluidity of the molten pool, and accelerate the heat transfer of the parent material on both sides of the weld, so as to obtain a faster weld and a deeper penetration at one time, so that the heat generated in the additive is more evenly distributed in the thickness direction, and at the same time, the distribution of residual stress can be changed to change the forming defects of the workpiece.

[0042] Especially in the molten pool behavior with crack defects, the heat input of the arc is large. Without swinging the arc, when the residual stress exceeds the local ultimate tensile strength of the material, the component will crack. The swinging arc is beneficial to the conduction of heat in the direction of the weld width, improving the fluidity of the molten pool, and increasing the side wall penetration depth during narrow gap welding. It can reduce residual stress, inhibit the generation of cracks in the weld, and at the same time reduce spatter during the material addition process.

[0043] After welding is completed, turn off the switches of the gas shielded welding power supply I, the gas shielded welding power supply II and the controller in sequence. Example

[0044] In the main wire swinging three-wire composite arc additive manufacturing device and method provided in this embodiment, the positive electrode of the consumable electrode gas shielded welding power source I is connected to the substrate, and the negative electrode is connected to the main wire welding gun; the positive electrode of the consumable electrode gas shielded welding power source II is connected to the auxiliary wire welding gun I, and the negative electrode is connected to the auxiliary wire welding gun II; The welding wire model of the main wire welding gun is ER5356, and the welding wire models of the auxiliary wire welding guns I and II are ER2319; the welding wire diameters of the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II are all 1.2 mm; the welding wires of the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II are arranged in a circle with an angle of 120°, and the angle between the welding wire and the horizontal plane is 45°.

[0045] During welding / additive manufacturing, the welding wires on the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II extend out of the welding gun by 13 mm, the intersection of the welding wires is 2 mm away from the substrate, the swing trajectory of the swinging arc is circular, and the swing frequency is 1 Hz.

Claims

1. A main wire swinging three-wire composite arc additive manufacturing device, characterized in that: It includes a gas shielded welding power source I, a gas shielded welding power source II, a main wire welding gun, an auxiliary wire welding gun I, an auxiliary wire welding gun II, a welding gun fixture, a wire feeding mechanism, a swing device, a base plate, and a controller; One electrode of the gas shielded welding power source I is connected to the main wire welding gun, and the other electrode is connected to the base plate. The output end of the gas shielded welding power source I is connected to a relay, and the positive and negative poles are switched through the relay switch; one electrode of the gas shielded welding power source II is connected to the auxiliary wire welding gun I, and the other electrode is connected to the auxiliary wire welding gun II. The output end of the gas shielded welding power source II is connected to a relay, and the positive and negative poles are switched through the relay switch; The welding gun fixture is equipped with three sets of angle adjustment mechanisms and welding gun clamping mechanisms, and the angles among the main wire welding gun, the auxiliary wire welding gun I, and the auxiliary wire welding gun II can be adjusted through the welding gun fixture; The swing device is located on the main wire welding gun and is used for swinging the welding wire in the main wire welding gun.

2. The main wire swinging three-wire composite arc additive manufacturing device according to claim 1 is characterized in that: The types of the gas metal arc welding power source I and the gas metal arc welding power source II are direct current or alternating current power sources.

3. The main wire swinging three-wire composite arc additive manufacturing device according to claim 1 is characterized in that: The welding gun clamping mechanism is responsible for clamping the welding gun, and the angle adjustment mechanism can adjust the angle between the welding gun and the horizontal plane within a range of 0-90°, and can also adjust the angle and distance between the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II, and can also adjust the height of the welding gun from the substrate.

4. The main wire swinging three-wire composite arc additive manufacturing device according to claim 1 is characterized in that: The swing device makes the main wire swing according to different tracks, frequencies and amplitudes, so that the generated composite arc swings in the width direction of the weld.

5. The main wire swinging three-wire composite arc additive manufacturing device according to claim 1 is characterized in that: The controller can control the swing device to swing in any trajectory, and can also control the frequency and amplitude of the swing.

6. The main wire swinging three-wire composite arc additive manufacturing device according to claim 1 is characterized in that: The welding wires in the main wire welding gun, the auxiliary wire welding gun I and the auxiliary wire welding gun II can be of the same kind of wire material or of different kinds of wire material.

7. A main wire swinging three-wire composite arc additive manufacturing method, characterized in that: The main wire swinging three-wire composite arc additive manufacturing device according to any one of claim 1 is used, comprising the following steps: Step 1: Pre-treat the substrate and place it in the position to be welded; extend the welding wires on the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II out of the welding gun by 0-25mm, and adjust the welding gun angle through the welding gun adjustment mechanism so that the initial positions of the welding wires on the main wire welding gun, auxiliary wire welding gun I, and auxiliary wire welding gun II intersect at one point; adjust the welding gun fixture so that the intersection of the welding wires is 0-20mm higher than the substrate. The working parameters are not limited to the above range; Step 2: Start the controller, which controls the current of the two gas shielded welding power supplies, the wire feeding speed, the substrate moving speed, the main wire swing form, the relay switch and other systems; Step 3: Simultaneously start the gas shielded welding power source I and the gas shielded welding power source II, a current loop is formed between the main wire welding gun and the base plate, a wire-to-plate arc is generated, a current loop is formed between the auxiliary wire welding gun I and the auxiliary wire welding gun II, an inter-wire arc is generated, and the wire-to-plate arc and the inter-wire arc are coupled to form a composite arc; Step 4: The controller controls the swing device to swing along a certain trajectory, frequency and amplitude. The swing device drives the main wire welding gun to swing, so that the composite arc formed by the wire-plate arc and the arc between wires swings at a certain frequency in the width direction of the weld. The composite swinging arc melts the welding wire to form molten droplets, which fall off and transition into the molten pool. As the substrate moves, a welding / additive process is completed. The swinging arc helps to stir the molten pool, improve the fluidity of the molten pool, and speed up the heat transfer of the parent material on both sides of the weld, so as to obtain a faster weld and a deeper penetration at one time, so that the heat generated in the additive is more evenly distributed in the thickness direction. At the same time, it can change the distribution of residual stress, thereby changing the forming defects of the workpiece and reducing the generation of cracks; Step 5: After welding is completed, turn off the switches of the gas shielded welding power supply I, the gas shielded welding power supply II, and the controller in sequence.

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