A Cu-Fe additive piece based on a wire-based directed energy deposition laminated structure, a preparation method and application thereof

Abstract

The application discloses a Cu-Fe additive piece based on a wire-based directed energy deposition laminated structure and a preparation method and application thereof, Cu welding wire and Fe welding wire are alternately deposited on a substrate by wire-based directed energy deposition technology to obtain a laminated structure Cu-Fe additive piece; the proportion of Cu and Fe elements in the additive piece is regulated by controlling the wire feeding speed, the fusion condition of the Cu and Fe deposition layer interface layer and the transition of alloy elements are regulated by controlling the welding current and voltage; the prepared Cu-Fe alloy additive piece has higher strength, hardness and electrical conductivity; the Cu-Fe additive piece prepared by using the wire-based directed energy deposition technology can solve the problem of performance decline caused by material metallurgical incompatibility in other preparation processes; compared with other additive processes, the Cu-Fe additive piece has the characteristics of relatively high deposition rate, low cost and small size limitation, and has great potential in building large structural parts with complex structures.

Description

Technical Field

[0001] This invention relates to a Cu-Fe additive manufacturing part with a directional energy deposition stack structure based on wire, its preparation method and application, belonging to the field of high-strength and high-conductivity copper alloy technology. Background Technology

[0002] High-performance copper alloys are key basic materials in high-tech fields such as next-generation information technology and advanced rail transit equipment, which are of great importance to my country's development. They possess a series of excellent properties, including high electrical conductivity, high thermal conductivity, high strength, high corrosion resistance, plating applicability, and ease of processing. The development of high-performance electromechanical equipment requires alloy materials with even higher strength and superior electrical conductivity. Cu-Fe alloys are a strategic basic material urgently needed for my country to develop a new generation of low-cost, high-performance Cu alloys.

[0003] Mechanical properties and electrical conductivity are the most striking and important characteristics of conductive metallic materials used in electrical engineering. However, these two properties are inherently contradictory in copper and its alloys. Due to their physical properties, strengthening one often comes at the expense of the other. Microstructural control of Cu-Fe alloys to achieve a balance between high strength and high electrical conductivity aligns with the current rapid economic development, the increasing demand for energy, and the core objective of enterprises to reduce costs.

[0004] Cu-Fe alloys exhibit a liquid-phase separation zone during cooling, which easily leads to defects such as segregation, shrinkage porosity, and shrinkage cavities during solidification. These defects severely affect the mechanical properties and electrical conductivity of Cu-Fe alloys, hindering their further development as high-performance copper alloys.

[0005] Directed energy deposition (DED) technology offers advantages such as adjustable melting temperature and short forming time, avoiding the uneven mixing and interdiffusion of Cu and Fe during high-temperature casting. This allows for the control of the Cu / Fe phase interface, resulting in a synergistic improvement in the mechanical properties and electrical conductivity of the additive parts.

[0006] Currently, there are no reports on the fabrication of Cu-Fe alloy additive parts with multilayer structures using wire and directional energy deposition (OED) technology. Furthermore, the methods for controlling the Cu / Fe phase interface and the composite mechanism, as well as the strengthening-conductivity mechanism of Cu-Fe heterostructures, have not been elucidated. Therefore, research on the fabrication of multilayer Cu-Fe additive parts using wire and OED technology, and its phase interface control, can provide a theoretical basis for the preparation of high-strength, high-conductivity Cu-Fe alloy materials and broaden their application fields. Summary of the Invention

[0007] Objectives of the Invention: To address the shortcomings of existing technologies, the first objective of this invention is to provide a Cu-Fe additive manufacturing part with a filament-based directional energy deposition (OED) multilayer structure. The second objective is to provide a method for fabricating this Cu-Fe additive manufacturing part with an OED multilayer structure. The third objective is to provide applications of this Cu-Fe additive manufacturing part with an OED multilayer structure in high-performance electromechanical equipment.

[0008] Technical solution: The present invention discloses a Cu-Fe additive manufacturing part based on filament-directed energy deposition stacked structure, which forms a Cu-Fe additive manufacturing part with alternating Cu and Fe stacked structure through filament-directed energy deposition technology.

[0009] Furthermore, wire-directed energy deposition technology includes gas metal arc welding (GMAW), non-GMAW, plasma arc welding, and / or cold metal transfer (CMT).

[0010] Furthermore, the heat source for directional energy deposition technology of filaments is a laser, an electron beam, a plasma arc, and / or an electric arc.

[0011] The method for fabricating a Cu-Fe additive component based on filament-driven directional energy deposition stack structure according to the present invention includes the following steps:

[0012] By using wire-directed energy deposition technology, Cu welding wire and Fe welding wire are alternately fed into the molten pool for deposition. By adjusting the welding current and voltage, the heat input of the current deposition layer can be controlled, which can effectively control the Cu / Fe phase interface width and the interfacial bonding strength.

[0013] Furthermore, Cu welding wire and Fe welding wire are doped with alloying elements, which are one or more of Si, V, Mn, Cr, Ni, Al, and rare earth elements.

[0014] Furthermore, the rare earth elements are Y, Gd, and / or Nd, etc.

[0015] Furthermore, during the Cu welding wire deposition process, the welding torch oscillates in a triangular wave along the direction of travel. By adjusting the oscillation amplitude and oscillation step size, Cu layer structures of different widths and thicknesses can be obtained.

[0016] Furthermore, the alternating Cu and Fe layered structure consists of more than one layer.

[0017] Furthermore, the wire feeding speed of Cu welding wire is 10-15 m / min, and the wire feeding speed of Fe welding wire is 8-12 m / min.

[0018] Furthermore, the welding current for Cu welding wire is 137–243 A, and the welding voltage is 11.6–23.5 V.

[0019] Furthermore, the welding current for Fe welding wire is 120–226A, and the welding voltage is 11.2–22.3V.

[0020] The present invention relates to the application of the Cu-Fe additive manufacturing process based on filament-driven directional energy deposition stack structure in high-performance electromechanical equipment.

[0021] This invention regulates the welding current and voltage to control the heat input of the current deposited layer, thereby controlling the microstructure, forming surface, interface bonding, and elemental transition at the interface of the Fe phase in the Cu deposited layer. This results in the formation of spherical and dendritic Fe phases with good interface bonding and no obvious defects. The fabricated Cu-Fe additive manufacturing parts include those with only one Cu and one Fe deposited layer, as well as those with multiple Cu and Fe deposited layers.

[0022] This invention, based on the preset ratio of Cu to Fe in the Cu-Fe additive part and the required Cu-Fe interface layer effect, sets the wire feeding speeds of Cu and Fe welding wires respectively. The Cu welding wire is used to deposit the first layer on the substrate. When the Cu deposition layer cools to 100°C, the welding wire is replaced with Fe welding wire while maintaining the same arc start and end points, and the welding torch is raised by 3mm to continue depositing the second layer. The deposition process is then repeated until the required additive part size is achieved. Under the action of heat input and arc agitation, the forming surface is affected by the next deposition layer and partially remelted. The Fe phase in the Cu deposition layer mainly exists in the form of micron-sized spherical and dendritic second phases. The interface between the Cu and Fe deposition layers is well bonded, resulting in a stacked Cu-Fe additive part.

[0023] This invention involves alternating deposition of Cu and Fe welding wires on a substrate to obtain a stacked Cu-Fe additive part. The Cu and Fe element ratios in the additive part are adjusted by controlling the wire feed speed, and the fusion state and element transition at the interface of the Cu and Fe deposition layers are controlled by adjusting the welding current and voltage. The prepared Cu-Fe alloy additive part exhibits higher strength, hardness, electrical conductivity, and work hardening capability compared to Cu-Fe ingots prepared by traditional casting methods. Utilizing directional energy deposition (GED) to prepare Cu-Fe additive parts can solve the performance degradation problem caused by material metallurgical incompatibility in other manufacturing processes. Furthermore, GED based on wires offers advantages over other additive manufacturing processes, including relatively high deposition rates, lower costs, and fewer size limitations, making it highly promising for constructing large structural components with complex structures.

[0024] Beneficial effects: Compared with the prior art, the present invention has the following significant advantages:

[0025] (1) In the Cu-Fe additive component based on directional energy deposition stacked structure of wire material, spherical Fe phase and dendritic Fe phase appear in Cu deposition layer. The interface between Cu deposition layer and Fe deposition layer is well bonded and there are no obvious defects.

[0026] (2) This invention, based on directional energy deposition of filament, features adjustable melting temperature and short forming time, avoiding uneven mixing and mutual diffusion of Cu and Fe during high-temperature casting. This effectively improves the mechanical properties of the material and reduces the risk of defects such as cracks and porosity in the components, thus meeting their safe service requirements. The achievement of low heat input and precise control of the filament quantity effectively regulates the mixing of Cu and Fe and the interface bonding between the Cu and Fe deposition layers.

[0027] (3) The Cu-Fe additive parts obtained by the present invention have a hardness of 190HV, a tensile strength of 382MPa in the construction direction, a tensile strength of 591MPa in the scanning direction, and an electrical conductivity of 68%IACS. The Cu-Fe additive parts prepared by the present invention using the directional energy deposition process have better tensile strength in both the construction direction and the scanning direction than the traditional casting method, and the hardness and electrical conductivity are increased by 58% and 30.7%, respectively. Attached Figure Description

[0028] Figure 1 Diagram of the directional energy deposition experimental platform;

[0029] Figure 2 A schematic diagram of the fabrication process of Cu-Fe alloy with directional energy deposition stack structure based on wire material;

[0030] Figure 3 This is a diagram of a Cu-Fe alloy additive manufacturing part with a directional energy deposition stack structure based on wire material;

[0031] Figure 4 The image shows the macroscopic cross-sectional morphology of a Cu-Fe alloy additive component with a directional energy deposition stack structure based on wire.

[0032] Figure 5 The image shows the metallographic structure at the interface of the Cu-Fe alloy additive manufacturing part with a laminated structure in Example 1.

[0033] Figure 6 The image shows the metallographic structure at the interface of the Cu-Fe alloy additive manufacturing part with a laminated structure in Example 2.

[0034] Figure 7 The image shows the metallographic structure at the interface of the Cu-Fe alloy additive manufacturing part with a laminated structure in Example 3.

[0035] Figure 8 The image shows the metallographic structure at the interface of the Cu-Fe alloy additive manufacturing part with a laminated structure in Example 4.

[0036] Figure 9 This is a macroscopic morphology diagram of the Cu-Fe alloy additive manufacturing part with a stacked structure in Example 5. Detailed Implementation

[0037] The technical solution of the present invention will be further described below with reference to the accompanying drawings.

[0038] Cu-Fe alloy additive parts were fabricated using a single-wire WAAM platform robot. The main experimental equipment included a FRONIUS digital pulse MIG / MAG welder-TPS4000 and an ABB industrial robot (such as...). Figure 1 (As shown).

[0039] The following experiments used a single-wire WAAM platform to alternately deposit commercially available 1mm diameter Cu welding wire SCu6180 and 0.8mm diameter Fe welding wire MG50-6 to obtain a stacked Cu-Fe additive manufacturing part. The additive manufacturing process was completed using CMT (Cold Metal Transfer) technology. All materials used in the following experiments were commercially available.

[0040] Example 1

[0041] like Figure 2 As shown, Cu-Fe additive manufacturing was first performed on a 45 steel substrate using Cu welding wire SCu6180 at a wire feed speed of 10 m / min, a welding current of 137 A, and a welding voltage of 11.6 V. After the current deposited layer (approximately 3 mm thick) cooled to 100 °C, Fe welding wire MG50-6 was used to deposit on the Cu-shaped surface, maintaining the same arc start and end points. The welding torch was raised by 3 mm, the Fe welding wire feed speed was 8 m / min, the welding current was 120 A, and the welding voltage was 11.2 V. A single-layer Cu-Fe additive part was obtained, as shown. Figure 3 As shown. Subsequently, Cu and Fe were deposited alternately with the same parameters until the desired number of additive manufacturing layers was reached. Ultimately, the Fe deposition layer accounted for 20.02% of the Cu-Fe additive manufacturing part. In this embodiment, a total of 17 layers were deposited, as shown... Figure 3-4 As shown.

[0042] Metallographic analysis was performed on the multilayer Cu-Fe additive part prepared in this embodiment, and the results are as follows: Figure 5 As shown. Figure 5 The results show that in the Cu-Fe additive manufacturing process of the laminated structure, the Fe phase in the Cu deposition layer mainly exists in the form of spherical and dendritic second phases, with slight protrusions at the Cu-Fe deposition layer interface. Performance tests show that the laminated Cu-Fe additive manufacturing process has a hardness of 172 HV, a tensile strength in the build direction of 363 MPa, a tensile strength in the scanning direction of 556 MPa, and an electrical conductivity of 61% IACS.

[0043] Example 2

[0044] The preparation process was the same as in Example 1, except for the control of wire feed speed, welding current, and welding voltage. First, Cu welding wire SCu6180 was used for additive manufacturing on a 45 steel substrate, with a wire feed speed of 12 m / min, a welding current of 196 A, and a welding voltage of 22.1 V. After the current deposited layer (approximately 3 mm thick) cooled to 100 °C, Fe welding wire MG50-6 was used for deposition on the Cu-shaped surface, maintaining the same arc start and end points and raising the welding torch by 3 mm. The Fe welding wire feed speed was 10 m / min, the welding current was 176 A, and the welding voltage was 16.5 V. Subsequently, deposition was continued alternately with the same parameters until the desired number of layers for the additive part was reached. Ultimately, the Fe deposition layer accounted for 23.46% of the Cu-Fe additive part.

[0045] Metallographic analysis was performed on the multilayer Cu-Fe additive part prepared in this embodiment, and the results are as follows: Figure 6 As shown. Figure 6 As shown in this embodiment, the Fe phase in the Cu deposition layer of the stacked Cu-Fe additive part mainly exists in the form of fine spherical and dendritic second phases. The interface between the Cu and Fe deposition layers is straight, well-bonded, and without obvious defects. Performance tests show that the stacked Cu-Fe additive part has a hardness of 190 HV, a tensile strength in the build direction of 382 MPa, a tensile strength in the scanning direction of 591 MPa, and an electrical conductivity of 68% IACS.

[0046] Example 3

[0047] The preparation process was the same as in Example 1, except for the control of wire feed speed, welding current, and welding voltage. First, Cu welding wire SCu6180 was used for additive manufacturing on a 45 steel substrate, with a wire feed speed of 15 m / min, a welding current of 243 A, and a welding voltage of 23.5 V. After the current deposited layer (approximately 3 mm thick) cooled to 100 °C, Fe welding wire MG50-6 was used for deposition on the Cu-shaped surface, maintaining the same arc start and end points and raising the welding torch by 3 mm. The Fe welding wire feed speed was 12 m / min, the welding current was 226 A, and the welding voltage was 22.3 V. Subsequently, deposition was continued alternately with the same parameters until the desired number of layers for the additive part was reached. Ultimately, the Fe deposition layer accounted for 25.76% of the Cu-Fe additive part.

[0048] Metallographic analysis was performed on the multilayer Cu-Fe additive part prepared in this embodiment, and the results are as follows: Figure 7 As shown. Figure 7As shown in this embodiment, the Fe phase in the Cu deposition layer of the stacked Cu-Fe additive part mainly exists in the form of spherical second phase and a small amount of dendritic second phase. Due to the large heat input and thermal cycling, the Fe phase distribution in the Cu deposition layer is uneven. Simultaneously, defects appear at the interface between the Cu and Fe deposition layers, and microcracks are generated in the Fe deposition layer. Performance testing shows that the stacked Cu-Fe additive part has a hardness of 149 HV, a tensile strength in the build direction of 345 MPa, a tensile strength in the scanning direction of 536 MPa, and an electrical conductivity of 56% IACS.

[0049] Example 4

[0050] The preparation process was the same as in Example 1, except for the control of wire feed speed, welding current, and welding voltage. First, S211 silicon bronze welding wire containing 3% silicon and 1% manganese was deposited on a 45 steel substrate. The wire feed speed was 15 m / min, the welding current was 243 A, and the welding voltage was 23.5 V. After the current deposited layer (approximately 3 mm thick) cooled to 100°C, Fe welding wire MG50-6 was used to deposit on the Cu-shaped surface, maintaining the same arc start and end points while raising the welding torch by 3 mm. The Fe welding wire feed speed was 12 m / min, the welding current was 226 A, and the welding voltage was 22.3 V. Subsequently, deposition was continued alternately with the same parameters until the desired number of additive manufacturing layers was reached. Ultimately, the Fe deposition layer accounted for 25.31% of the Cu-Fe additive manufacturing part.

[0051] Metallographic analysis was performed on the multilayer Cu-Fe additive part prepared in this embodiment, and the results are as follows: Figure 8 As shown. Figure 8 As shown in this embodiment, the Cu deposited layer in the stacked Cu-Fe additive part exhibits a large amount of dendritic Fe phase and a small amount of spherical Fe second phase. Simultaneously, a large protruding region appears at the interface between the Cu and Fe deposited layers. Performance testing reveals that the stacked Cu-Fe additive part has a hardness of 162 HV, a tensile strength in the build direction of 377 MPa, a tensile strength in the scanning direction of 547 MPa, and an electrical conductivity of 59% IACS.

[0052] Example 5

[0053] The preparation process is the same as in Example 1, except for the control of wire feed speed, welding current, and welding voltage. First, Cu welding wire SCu6180 is used for additive manufacturing on the substrate, with a wire feed speed of 7 m / min, a welding current of 112 A, and a welding voltage of 10.3 V. After the current deposited layer (approximately 3 mm thick) cools to 100°C, Fe welding wire MG50-6 is used for deposition on the Cu-shaped surface, maintaining the same arc start and end points and raising the welding torch by 3 mm. The Fe welding wire feed speed is 6 m / min, the welding current is 103 A, and the welding voltage is 10.8 V. Subsequently, deposition continues alternately with the same parameters until the preset number of additive manufacturing layers is reached. In this example, due to the excessively low welding current and voltage parameters, the welding heat input is insufficient, resulting in poor forming of the Cu-Fe alloy additive manufacturing part, which fails to meet the required additive manufacturing requirements. Figure 9 As shown.

[0054] Comparative Example 1

[0055] Traditional casting processes use pure Cu (99.95 wt%) and Fe (99.99 wt%) in a desired ratio of Cu80Fe20 to produce Cu-Fe alloy workpieces. Cu and Fe metal ingots with a ratio of 80% Cu and 20% Fe are placed in an electric arc melting furnace for pre-alloying, with the furnace chamber repeatedly evacuated and purged using high-purity argon. To ensure alloy homogeneity, the sample is repeatedly melted three times. The alloy is then remelted in a ceramic crucible via induction melting and poured into a prepared mold. The final Cu-Fe alloy workpiece has a hardness of 120 HV, a tensile strength of 340 MPa, and an electrical conductivity of 52% IACS.

[0056] The process parameters and performance results of Examples 1-5 and Comparative Example 1 are shown in Table 1.

[0057] Table 1. Parameters and performance of arc additive manufacturing

[0058]

[0059] As shown in Table 1, in the embodiments of the present invention, the Cu-Fe additive part with the best performance reaches a hardness of 190 HV, a tensile strength in the build direction of 382 MPa, a tensile strength in the scanning direction of 591 MPa, and an electrical conductivity of 68% IACS. The Cu-Fe additive part prepared by the directional energy deposition process of the present invention has better tensile strength in both the build direction and the scanning direction than the traditional casting method, and the hardness and electrical conductivity are improved by 58% and 30.7%, respectively.

[0060] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A method for fabricating a Cu-Fe additive component with a directional energy deposition stack structure based on filament material, characterized in that, Cu-Fe additive parts with alternating Cu and Fe layers are formed using wire-directed energy deposition technology; Its preparation method includes the following steps: Using wire-directed energy deposition technology, Cu and Fe welding wires are alternately fed into the molten pool for deposition. By adjusting the welding current and voltage, the heat input of the current deposition layer can be controlled, which can effectively control the Cu / Fe phase interface width and interfacial bonding strength. The wire feeding speed of Cu welding wire is 10~15 m / min, the wire feeding speed of Fe welding wire is 8~12 m / min, the welding current of Cu welding wire is 137~243 A, and the welding voltage is 11.6~23.5 V, while the welding current of Fe welding wire is 120~226 A and the welding voltage is 11.2~22.3 V.

2. The preparation method according to claim 1, characterized in that, Directional energy deposition technology for wires includes gas metal arc welding (GMAW), non-GMAW, plasma arc welding, and / or cold metal transfer technology.

3. The preparation method according to claim 1, characterized in that, The heat source for directional energy deposition technology of filaments is laser, electron beam, plasma arc and / or electric arc.

4. The preparation method according to claim 1, characterized in that, Both Cu and Fe welding wires are doped with alloying elements, which are one or more of Si, V, Mn, Cr, Ni, Al, and rare earth elements.

5. The preparation method according to claim 1, characterized in that, During the Cu welding wire deposition process, the welding torch oscillates in a triangular wave along the direction of travel. By adjusting the oscillation amplitude and oscillation step size, Cu layer structures of different widths and thicknesses can be obtained.

6. The preparation method according to claim 1, characterized in that, The alternating Cu and Fe layered structure consists of more than one layer.

7. The Cu-Fe additive manufacturing part with a directional energy deposition stacked structure based on filament obtained by the preparation method according to any one of claims 1-6, characterized in that, Application of this additive component in high-performance electromechanical equipment.

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