Additive manufacturing apparatus and method for additive parts, composite structural parts by friction stir deposition

Abstract

This invention discloses an additive manufacturing apparatus and method for additive components and composite structural parts using friction stir deposition (FSD). The additive component has an axial direction and a feeding channel. The feeding channel extends through the additive component along the axial direction and includes a first part, a second part, and a third part arranged sequentially and connected along the axial direction. The diameter of the first part is larger than the diameter of the third part. A discharge port is formed at the end of the third part away from the second part. The diameter of the second part gradually decreases in the direction from the first part to the third part. This invention enables the manufacture of irregularly shaped composite structural parts using FSD. The composite structural parts can be formed in one step without plastic processing, reducing production steps, improving preparation efficiency, and ensuring the stability of the deposition process. This meets the requirements for one-step preparation of complex irregularly shaped composite structural parts and also prevents the formation of intermetallic compounds within the composite structural parts, improving the stability and product yield.

Description

Technical Field

[0001] This invention relates to the field of friction stir deposition additive manufacturing technology, and in particular to an apparatus and method for friction stir deposition additive manufacturing of additive components and composite structural parts. Background Technology

[0002] Composite structural components, being made of composite materials, possess high specific strength and functional properties, thus having a wide range of applications. For example, titanium / aluminum composite structural components have great application prospects in the 3C electronics field. Apple's iPhone 15 Pro, released in 2023, replaced the previous aluminum alloy body with a titanium / aluminum composite frame, reducing weight by 9g while maintaining the original strength.

[0003] In related technologies, composite structural components require the initial rolling of laminated metal sheets of different materials using composite plate rolling technology to obtain composite plates. Then, the composite plates are machined using methods such as bending and milling to obtain the target shape of the composite structural component. For some irregularly shaped composite structural components, there are often curved or folded corners. Therefore, the prepared composite plates require further processing; for example, the composite plates need to be bent to form irregularly shaped composite structural components with curved corners. However, this forming process is complex and has low production efficiency. Furthermore, because composite structural components generally have poor plastic deformation capacity, controlling the bending angle is difficult. During the manufacturing process, intermetallic compounds are formed through interfacial metallurgical reactions to achieve interfacial bonding. During bending, the interface of the composite material is prone to cracking along these brittle and hard intermetallic compounds, resulting in a low product yield. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. Therefore, one object of the present invention is to provide an additive manufacturing component that can improve the manufacturing efficiency of composite structural components and improve the molding quality and product yield of the composite structural components.

[0005] The present invention also aims to provide a stir friction deposition additive manufacturing apparatus for composite structural components to utilize the above-mentioned additive components.

[0006] The present invention also aims to provide a method for manufacturing composite structural components by friction stir deposition additive manufacturing, using the above-mentioned apparatus for manufacturing composite structural components by friction stir deposition additive manufacturing.

[0007] According to an embodiment of the present invention, an additive component is used in a friction stir deposition additive manufacturing apparatus for composite structural components. The additive component has an axial direction and a feeding channel. The feeding channel extends through the additive component along the axial direction and includes a first part, a second part, and a third part that are sequentially arranged and connected along the axial direction. The diameter of the first part is larger than the diameter of the third part. An outlet is formed at the end of the third part away from the second part. The diameter of the second part gradually decreases in the direction from the first part to the third part.

[0008] According to the additive manufacturing component of the present invention, composite structural parts with irregular shapes can be manufactured by friction stir deposition additive manufacturing. The composite structural parts can be formed in one step without plastic processing, reducing production steps, improving manufacturing efficiency, and ensuring the stability of the deposition process, thus meeting the requirements for one-step manufacturing of complex irregular-shaped composite structural parts. During the manufacturing process, the additive manufacturing component does not need to rotate with the rod, avoiding process instability caused by component rotational vibration, improving process applicability and stability. Furthermore, the low heat input and large plastic deformation characteristics of the additive manufacturing component during friction stir deposition additive manufacturing also prevent the formation of intermetallic compounds within the composite structural part, thereby improving the stability and product yield of the composite structural part.

[0009] In some embodiments of the present invention, the second portion is configured such that the roughness of its inner wall surface is greater than that of the inner wall surface of the first portion.

[0010] In some embodiments of the present invention, the inner wall surface of the second part is constructed as at least one of an arc-shaped wall surface, a curved wall surface, and a conical wall surface.

[0011] In some embodiments of the present invention, the inner wall surface of the second part is constructed as a multi-step structure.

[0012] In some embodiments of the present invention, the multi-step structure includes multiple step portions, each step portion including a first surface and a second surface that are perpendicular and connected, the second surface being parallel to the axial direction, and the distance difference between any two adjacent second surfaces being T, wherein 2mm≤T≤5mm.

[0013] In some embodiments of the present invention, the height of the second surface in the axial direction is H, wherein 1mm≤H≤6mm.

[0014] In some embodiments of the present invention, along the axial direction, the length of the first portion is greater than the length of the second portion, and the length of the second portion is greater than the length of the third portion.

[0015] In some embodiments of the present invention, the additive component includes a first segment and a second segment connected together, the second segment being a rotating body structure, the first part being disposed within the first segment, the second part and the third part being disposed within the second segment, and the diameter of the second segment gradually decreasing in the direction from the first part to the third part.

[0016] According to an embodiment of the present invention, a composite structural component friction stir deposition additive manufacturing apparatus includes an additive component as described in any one of the preceding descriptions.

[0017] The composite structural component friction stir deposition additive manufacturing apparatus according to embodiments of the present invention can realize the fabrication of irregularly shaped composite structural components by friction stir deposition additive manufacturing method. The composite structural components can be formed in one step without plastic processing, which can reduce production steps, improve preparation efficiency, and ensure the stability of the deposition process, thereby meeting the one-step fabrication requirements of complex irregularly shaped composite structural components. Due to the low heat input and large plastic deformation characteristics of friction stir deposition additive manufacturing, the formation of intermetallic compounds within the composite structural components can also be prevented, improving the stability of the composite structural components and the product yield.

[0018] According to an embodiment of the present invention, a method for manufacturing a composite structural component using friction stir deposition additive manufacturing apparatus as described above is provided. The composite structural component includes a substrate layer and an additive layer stacked together. The substrate layer has a corner position. The method includes: keeping the additive component stationary at a preset height from the corner position of the substrate layer; feeding a rod into the feeding channel of the additive component and feeding it along the axial direction at a preset rotation speed; rotating the rod and contacting a second part of the feeding channel to generate heat through frictional deformation and directly thermoplasticize it, and extruding it from the outlet; depositing the extruded thermoplasticized material at the corner position of the substrate layer and filling the space between the additive component and the substrate layer; simultaneously forging the deposited layer by the additive component to obtain the additive layer on the substrate layer; and moving the additive component along a preset path.

[0019] The composite structural component friction stir deposition additive manufacturing method according to embodiments of the present invention enables the fabrication of irregularly shaped composite structural components using this method. The composite structural components can be formed in a single step, improving manufacturing efficiency and ensuring the stability of the deposition process, thus meeting the requirements for one-step fabrication of complex irregularly shaped composite structural components. Due to the low heat input and large plastic deformation characteristics of friction stir deposition additive manufacturing, the formation of intermetallic compounds within the composite structural component can be prevented, thereby improving the stability and product yield of the composite structural component.

[0020] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0021] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0022] Figure 1 A three-dimensional structural schematic diagram of an additive component provided in some embodiments of the present invention;

[0023] Figure 2 This is a cross-sectional view of the internal structure of an additive component provided in some embodiments of the present invention;

[0024] Figure 3 This is a partial structural schematic diagram of an additive component provided in some embodiments of the present invention;

[0025] Figure 4 for Figure 2 A magnified view of section IV;

[0026] Figure 5 Schematic diagram of additive manufacturing of composite structural parts according to some embodiments of the present invention Figure 1 ;

[0027] Figure 6 Schematic diagram of additive manufacturing of composite structural parts according to some embodiments of the present invention Figure 2 ;

[0028] Figure 7 A flowchart illustrating a method for manufacturing composite structural parts by friction stir deposition additive manufacturing according to some embodiments of the present invention;

[0029] Figure 8 A cross-sectional topography of a composite structure prepared by the friction stir deposition additive manufacturing method of the present invention.

[0030] Figure 9 The image shows the interface microstructure of a composite structural component prepared using composite plate rolling technology in accordance with related technologies.

[0031] Figure 10 This image shows the interface microstructure of a composite structure manufactured using the friction stir deposition additive manufacturing method of this invention.

[0032] Figure label:

[0033] 10. Additive components;

[0034] 101. Feeding channel; 1011. First section; 1012. Second section; 1013. Third section; 1013a. Discharge port; 102. Multi-stage stepped structure; 1021. Stepped section; 10211. First surface; 10212. Second surface; 103. Shoulder; 104. Clamping part; 11. First section; 12. Second section;

[0035] 20. Composite structural components;

[0036] 201, Substrate layer; 2011, Corner position; 202, Additive layer.

[0037] 30. Bar stock. Detailed Implementation

[0038] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0039] In the description of this invention, it should be understood that the terms "center," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, features defined with "first" and "second" may explicitly or implicitly include one or more of these features, used to distinguish descriptive features, without any order or emphasis.

[0040] In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0041] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0042] The additive component 10 of an embodiment of the present invention will now be described with reference to the accompanying drawings.

[0043] like Figure 1 and Figure 2 As shown, according to an embodiment of the present invention, an additive component 10 is used in a composite structural component friction stir deposition additive manufacturing apparatus. The additive component 10 has an axial direction F1 and a feeding channel 101. The feeding channel 101 extends through the additive component 10 along the axial direction F1. The feeding channel 101 includes a first part 1011, a second part 1012, and a third part 1013 that are sequentially arranged and connected along the axial direction F1. The diameter of the first part 1011 is larger than the diameter of the third part 1013. An outlet 1013a is formed at the end of the third part 1013 away from the second part 1012. In the direction from the first part 1011 to the third part 1013, the diameter of the second part 1012 gradually decreases.

[0044] The additive component 10 can refer to a component used for feeding materials in a composite structure friction stir deposition additive manufacturing apparatus, and can forge the deposited layer. Its function is similar to that of the stirring head in friction stir welding in related technologies, but it is not the same as the stirring head in the prior art. Among them, a shoulder 103 can be formed at the bottom of the additive component 10, and the shoulder 103 can forge the deposited layer.

[0045] The axial direction F1 of the additive component 10 can be referenced. Figure 1 and Figure 2 The feeding channel 101 can refer to a channel for feeding the bar 30. In the above embodiment, the shape of the additive component 10 can be, but is not limited to, a cylindrical or polygonal prism shape, etc., and no specific limitation is made here. For example, as... Figure 1 The additive component 10 can be cylindrical.

[0046] In friction stir deposition additive manufacturing, the rod 30 is fed into the feed channel 101 of the additive component 10 and rotates at a preset speed. During this process, the additive component 10 remains stationary and does not rotate with the rod 30. Because the second part 1012 in the feed channel 101 receives the first part 1011 and the third part 1013, and the diameter of the second part 1012 gradually decreases, the rod 30 exerts significant pressure on the inner wall of the second part 1012 during axial feeding along the F1 direction. This generates considerable frictional heat between the rod 30 and the inner wall of the second part 1012 during rotation, causing the rod 30 to undergo thermoplastic deformation and be extruded from the outlet 1013a. The rod 30 can undergo thermoplastic deformation and material deposition without contacting the substrate or the previous deposition layer. In other words, the additive component 10 of this invention can manufacture the desired structural parts by extruding thermoplastic material onto the substrate or the previous deposition layer. When manufacturing a composite structural component 20 with an irregular shape, an additive layer 202 can be deposited at the arc-shaped or corner position of the substrate layer 201 of the irregular shape using the additive component 10, thereby obtaining the composite structural component 20. Thus, the composite structural component 20 with an irregular shape can be manufactured by the friction stir deposition additive method.

[0047] Compared to conventional friction stir deposition additive manufacturing, which uses a high-speed rotating rod to generate heat through friction with a substrate to achieve thermoplastic deposition and prepare composite structural parts, especially for irregularly shaped composite structural parts, the end face of the rod cannot effectively rub against the substrate due to the influence of the arc position and / or the angle position. This results in insufficient frictional heat generation and makes it difficult to achieve effective deposition. In other words, conventional friction stir deposition additive manufacturing is more difficult for irregularly shaped composite structural parts.

[0048] In this invention, when the composite structural component 20 is manufactured using friction stir deposition additive manufacturing via the additive component 10, especially for irregularly shaped composite structural components 20, the rod 30 rotates at high speed within the feeding channel 101. The rod 30 generates heat through friction with the inner wall of the second part 1012, allowing for pre-thermoplasticization of the rod 30 within the second part 1012. The extruded thermoplasticized material can then be directly deposited at the arc-shaped and / or angled positions of the irregularly shaped structure in the substrate layer 201, achieving one-time molding. Furthermore, since the rod 30 does not need to contact the substrate layer 201 for frictional heat generation during friction stir deposition additive manufacturing, the heat input is lower than that of conventional friction stir deposition additive manufacturing. This suppresses the formation of intermetallic compounds between the composite material interfaces of the composite structural component 20, improving the molding quality of the composite structural component 20.

[0049] It should be noted that the composite structural component 20 mentioned in this invention may include, but is not limited to, titanium / aluminum composite structural components. The composite structural component 20 may be a composite material structure of two or more other materials, and no specific limitations are made here.

[0050] According to the additive component 10 of the present invention, a composite structural part 20 with an irregular shape can be manufactured by friction stir deposition additive manufacturing. The composite structural part 20 can be formed in one step without plastic processing, which can reduce production steps, improve preparation efficiency, and ensure the stability of the deposition process, thereby meeting the one-step molding requirements of the complex irregular structure composite structural part 20. During the manufacturing process, the additive component 10 does not need to rotate with the rod 30, which can avoid the problem of process instability caused by the rotation and vibration of the additive component 10, improve the applicability and stability of the process. Through the low heat input and large plastic deformation characteristics of the additive component 10 during friction stir deposition additive manufacturing, it can also prevent the formation of intermetallic compounds in the composite structural part 20, thereby improving the stability of the composite structural part 20 and the product yield.

[0051] In some embodiments of the invention, the second portion 1012 is configured such that the roughness of its inner wall surface is greater than that of the inner wall surface of the first portion 1011.

[0052] The inner wall surface of the first part 1011 can be a smooth surface, while the inner wall surface of the second part 1012 can be a rough surface with a certain degree of roughness. For example, the inner wall surface of the second part 1012 can be textured or have raised dots. Alternatively, both the inner wall surfaces of the first part 1011 and the second part 1012 can be rough surfaces, but the roughness of the inner wall surface of the second part 1012 should be greater than that of the inner wall surface of the first part 1011. The inner wall surface of the third part 1013 can be either a smooth surface or a rough surface; no specific restrictions are placed here.

[0053] In the above technical solution, by setting the roughness of the inner wall surface of the second part 1012 to be relatively large, the frictional force between the rod 30 and the inner wall surface of the second part 1012 when rotating can be increased, thereby increasing the frictional heat generation, which is beneficial to the early and full thermoplasticization of the rod 30, thereby improving the product molding quality and yield.

[0054] In some embodiments of the present invention, such as Figure 3 As shown, the inner wall surface of the second part 1012 is constructed as at least one of an arc-shaped wall surface, a curved wall surface, and a conical wall surface.

[0055] like Figure 3 As shown in (a), the inner wall surface of the second part 1012 is constructed as an arc-shaped wall surface. Figure 3 As shown in (b), the inner wall surface of the second part 1012 is constructed as a curved wall surface. Figure 3As shown in (c), the inner wall surface of the second part 1012 is constructed as a conical wall surface.

[0056] In the above technical solution, by setting the inner wall surface of the second part 1012 into the above shape, more design options for the second part 1012 can be provided, and the design flexibility of the second part 1012 can be improved to meet different usage needs.

[0057] In some embodiments of the present invention, such as Figure 4 As shown, the inner wall surface of the second part 1012 is constructed as a multi-step structure 102. It can be understood that by setting the multi-step structure 102, the inner wall surface of the second part 1012 can have a greater roughness, thereby generating more heat through frictional deformation when the rod 30 and the inner wall surface of the second part 1012 come into contact and rotate, which is more conducive to the thermoplasticization of the rod 30.

[0058] In some embodiments of the present invention, such as Figure 4 As shown, the multi-step structure 102 includes multiple step sections 1021. Each step section 1021 includes a first surface 10211 and a second surface 10212 that are perpendicular and connected. The second surface 10212 is parallel to the axial direction F1. The distance difference between any two adjacent second surfaces 10212 is T, where 2mm≤T≤5mm.

[0059] It is understood that T can be, but is not limited to, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, etc. Among the multiple stepped portions 1021 arranged sequentially along the axial direction F1, the distance difference between any two adjacent second surfaces 10212 can be equal or unequal; no specific restriction is imposed here. The number of stepped portions 1021 can be set as needed; for example, the number of stepped portions 1021 can be 5 to 10.

[0060] In the above technical solution, by setting the distance difference between any two adjacent second surfaces 10212 in the multiple stepped portions 1021 within the above range, the inner wall surface of the second portion 1012 can have a suitable roughness to meet different friction deformation heat generation requirements, which is beneficial to the manufacture of composite structural parts 20 made of different materials.

[0061] In some embodiments of the present invention, such as Figure 4 As shown, in the axial direction F1, the height of the second surface 10212 is H, where 1mm≤H≤6mm.

[0062] It is understood that H can be, but is not limited to, 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, 6mm, etc. The heights of multiple second surfaces 10212 can be equal or unequal; no specific restrictions are imposed here.

[0063] In the above technical solution, by setting the height of the second surface 10212 within the above range and coordinating it with the distance difference between any two adjacent second surfaces 10212, the roughness of the inner wall surface of the second part 1012 can be further adjusted to meet different friction deformation heat generation requirements.

[0064] In some embodiments of the present invention, such as Figure 2 As shown, along the axial direction F1, the length of the first part 1011 is greater than the length of the second part 1012, and the length of the second part 1012 is greater than the length of the third part 1013.

[0065] The length of the second part 1012 in the above structure is suitable, so that the second part 1012 is relatively close to the discharge port 1013a. The thermoplasticized part of the rod 30 can be quickly extruded from the discharge port 1013a and deposited on the substrate layer 201 or the previous deposition layer. The first part 1011 and the third part 1013 are both circular channels of equal diameter.

[0066] In some embodiments of the present invention, such as Figure 2 As shown, the additive component 10 includes a first section 11 and a second section 12 connected together. The second section 12 is a rotating structure. The first part 1011 is disposed in the first section 11, and the second part 1012 and the third part 1013 are disposed in the second section 12. In the direction from the first part 1011 to the third part 1013, the diameter of the second section 12 gradually decreases.

[0067] The first section 11 can refer to a non-rotational or rotational structure. For example, the first section 11 can be, but is not limited to, a square column, a cylinder, etc. The second section 12 is a rotational structure. For example, the second section 12 can be a frustum or a curved column.

[0068] "In the direction from the first part 1011 to the third part 1013, the diameter of the second segment 12 gradually decreases." This can be understood as the second segment 12 having a frustum-shaped structure, or a structure with an arc-shaped circumferential surface, or a structure with a curved circumferential surface. This structure results in a relatively small width for the second segment 12, making it suitable for operation in confined spaces.

[0069] In the above technical solution, by setting the additive component 10 into the above structure, when manufacturing the irregularly shaped composite structural component 20, since the diameter of the second section 12 gradually decreases, the additive component 10 can adapt to the narrow space of the arc position or the corner position, which can prevent the additive component 10 from interfering with the irregular structure of the composite structural component 20. This is beneficial to reduce the distance between the discharge port 1013a and the substrate layer 201 or the previous deposition layer, which facilitates the manufacturing and molding of the composite structural component 20 and also helps to improve the molding quality of the composite structural component 20.

[0070] In some embodiments of the present invention, reference is made to... Figure 1 and Figure 2 The additive component 10 is provided with a clamping part 104, which is arranged in a ring around the circumference of the additive component 10. By providing the clamping part 104, the clamping part 104 can be fixed in the composite structure friction stir deposition additive manufacturing apparatus by bolts, which facilitates the installation of the additive component 10 into the composite structure friction stir deposition additive manufacturing apparatus.

[0071] A specific embodiment of the additive component 10 of the present invention is described below.

[0072] like Figure 1 , Figure 2 and Figure 4 The additive manufacturing component 10 is used in a friction stir deposition additive manufacturing apparatus for composite structural components. The additive manufacturing component 10 has an axial direction F1 and a feeding channel 101. The feeding channel 101 extends through the additive manufacturing component 10 along the axial direction F1. The feeding channel 101 includes a first part 1011, a second part 1012, and a third part 1013, which are sequentially arranged and connected along the axial direction F1. The diameter of the first part 1011 is larger than the diameter of the third part 1013. An outlet 1013a is formed at the end of the third part 1013 away from the second part 1012. The diameter of the second part 1012 gradually decreases in the direction from the first part 1011 to the third part 1013. The inner wall surface of the second part 1012 is constructed as a multi-step structure 102.

[0073] According to an embodiment of the present invention, a composite structural component friction stir deposition additive manufacturing apparatus includes an additive component 10 as described above.

[0074] It should be noted that the composite structural component friction stir deposition additive manufacturing apparatus may also include, but is not limited to, a feeding system, a control drive, a substrate fixing system, a heating system, a cooling system, a monitoring system, etc. The above structures can be referenced from related friction stir deposition additive manufacturing apparatuses, and will not be elaborated further here. Other components and operations of the composite material friction stir deposition additive manufacturing apparatus of this invention are known to those skilled in the art and will not be described in detail here.

[0075] The composite structural component friction stir deposition additive manufacturing apparatus according to embodiments of the present invention can manufacture irregularly shaped composite structural components 20 by friction stir deposition additive manufacturing. The composite structural component 20 can be formed in one step without plastic processing, which can reduce production steps, improve preparation efficiency, and ensure the stability of the deposition process, thereby meeting the one-step preparation requirements of complex irregularly shaped composite structural components 20. Due to the low heat input and large plastic deformation characteristics of friction stir deposition additive manufacturing, the formation of intermetallic compounds within the composite structural component 20 can also be prevented, improving the stability of the composite structural component 20 and the product yield.

[0076] like Figures 5 to 7 As shown, according to an embodiment of the present invention, a method for manufacturing a composite structural component using friction stir deposition additive manufacturing apparatus as described above is presented. The composite structural component 20 includes a substrate layer 201 and an additive layer 202 stacked together, wherein the substrate layer 201 has a corner position 2011. The method includes:

[0077] Step S1: Keep the additive component 10 stationary and stop at a preset height position 2011 at the corner of the substrate layer 201.

[0078] Step S2: Feed the bar 30 into the feeding channel 101 of the additive manufacturing component 10, and feed it along the axial direction F1 at a preset speed.

[0079] In the above steps, the material of the rod 30 is set as needed. For example, when the composite structural component 20 is a titanium / aluminum composite material, the substrate layer 201 can be a titanium plate, the additive layer 202 is an aluminum layer, and the rod 30 is an aluminum rod. The diameter of the rod 30 can be 5mm to 30mm. The feed speed of the rod 30 along the axial direction F1 can be 1mm / s to 30mm / s, and the preset rotational speed of the rod 30 can be 50rpm to 1000rpm. The diameter of the feeding channel 101 can be slightly larger than the diameter of the rod 30.

[0080] In step S3, the bar 30 rotates and comes into contact with the second part 1012 of the feeding channel 101, generating heat through frictional deformation to directly thermoplasticize it, and then extrudes it from the outlet 1013a.

[0081] Step S4: The extruded thermoplastic material is deposited at the corner position 2011 of the substrate layer 201 and fills the space between the additive component 10 and the substrate layer 201. At the same time, the additive component 10 forges the deposited layer to obtain the additive layer 202 on the substrate layer 201.

[0082] In the above steps, the thermoplasticized portion of the rod 30 can be deposited in the gap between the shoulder 103 of the additive component 10 and the substrate layer 201 after extrusion. At the same time, the shoulder 103 can also forge the deposited layer, which can better bond the substrate layer 201 and the additive layer 202, thereby obtaining a stable and reliable additive layer 202 on the substrate layer 201.

[0083] Step S5: Move the additive component 10 along the preset path.

[0084] In the above steps, the preset path can be selected based on the shape of the composite structural component 20. For example, the preset path can be a straight line, a curve, a serpentine shape, etc., without specific limitations. After the additive component 10 travels along the preset path in the above steps, the desired composite structural component 20 can be obtained.

[0085] like Figure 8 As shown, Figure 8 The figure shows a cross-sectional topography of the composite structure 20 prepared by the friction stir deposition additive manufacturing method of the present invention. As can be seen from the figure, the prepared composite structure 20 is dense and defect-free, which is beneficial to meet the high-quality one-time molding requirement of the composite structure 20, and no subsequent bending or other mechanical processing is required.

[0086] like Figure 9 and Figure 10 As shown, where, Figure 9 The image shows the interface microstructure of a composite structural component prepared using composite plate rolling technology. As can be seen in the image, intermetallic compounds are generated between the interfaces. Figure 10 The image shows the interface microstructure of a composite structure manufactured using the friction stir deposition additive manufacturing method of this invention. As can be seen from the image, no intermetallic compounds are generated between the interfaces, which can improve the interfacial bonding strength of the composite material.

[0087] It is understood that when the composite structural component is manufactured by the friction stir deposition additive manufacturing method of the present invention, the static state of the additive component 10 can improve the stability of the deposition process and prevent problems such as tooling interference caused by the rotation and vibration of the additive component 10. The composite structural component 20 with irregular structure manufactured by friction stir deposition additive manufacturing can be formed in one step without bending or other machining, which can avoid damage to the performance of composite materials by machining, reduce production steps and costs, and improve production efficiency. No intermetallic compounds are generated at the interface of the composite structural component 20, which can improve the stability of the composite material.

[0088] According to the composite structural component friction stir deposition additive manufacturing method of the present invention, a composite structural component 20 with irregular structure can be manufactured by friction stir deposition additive manufacturing. The composite structural component 20 can be formed in one step, improving the manufacturing efficiency and ensuring the stability of the deposition process, thus meeting the one-step manufacturing requirements of the complex irregular structure composite structural component 20. Due to the low heat input and large plastic deformation characteristics of friction stir deposition additive manufacturing, the formation of intermetallic compounds within the composite structural component 20 can also be prevented, thereby improving the stability and product yield of the composite structural component 20.

[0089] In the description of this specification, references to terms such as "some embodiments," "optionally," "furthermore," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0090] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An additive component for use in a stir friction deposition additive manufacturing apparatus for composite structural parts, characterized in that, The additive component has an axial direction and a feeding channel. The feeding channel extends through the additive component along the axial direction and includes a first part, a second part, and a third part arranged sequentially and connected along the axial direction. The diameter of the first part is larger than the diameter of the third part. An outlet is formed at the end of the third part away from the second part. The diameter of the second part gradually decreases in the direction from the first part to the third part. The inner wall of the second part is constructed as a multi-step structure, which includes multiple stepped portions arranged sequentially along the axial direction. A rod is fed into the feeding channel of the additive component and fed along the axial direction at a preset rotation speed. The rod rotates and contacts the second part of the feeding channel, generating heat through frictional deformation and directly thermoplasticizing it, and then extruding it from the outlet.

2. The additive manufacturing component according to claim 1, characterized in that, The second part is configured such that the roughness of the inner wall surface is greater than that of the inner wall surface of the first part.

3. The additive component according to claim 1, characterized in that, Each of the stepped portions includes a first surface and a second surface that are perpendicular and connected, the second surface being parallel to the axial direction, and the distance difference between any two adjacent second surfaces being T, wherein 2mm≤T≤5mm.

4. The additive component according to claim 3, characterized in that, In the axial direction, the height of the second surface is H, where 1mm ≤ H ≤ 6mm.

5. The additive component according to claim 1, characterized in that, Along the axial direction, the length of the first part is greater than the length of the second part, and the length of the second part is greater than the length of the third part.

6. The additive component according to any one of claims 1 to 5, characterized in that, The additive component includes a first section and a second section connected together. The second section is a rotating structure. The first part is located within the first section, and the second part and the third part are located within the second section. The diameter of the second section gradually decreases in the direction from the first part to the third part.

7. A stir friction deposition additive manufacturing apparatus for composite structural components, characterized in that, Includes the additive component as described in any one of claims 1 to 6.

8. A method for additive manufacturing of composite structural components by friction stir deposition, characterized in that, The composite structural component is manufactured using the composite structural component friction stir deposition additive manufacturing apparatus as described in claim 7. The composite structural component includes a substrate layer and an additive layer stacked together, the substrate layer having corner positions. The method includes: Keep the additive component stationary and stop it at a preset height position away from the corner of the substrate layer; The bar is fed into the feeding channel of the additive component and fed along the axial direction at a preset rotation speed; The bar rotates and contacts the second part of the feeding channel, generating heat through frictional deformation to directly thermoplasticize it, and then extrudes it from the outlet. The extruded thermoplastic material is deposited at the corner of the substrate layer and fills the space between the additive component and the substrate layer. The additive component simultaneously forges the deposited layer to form the additive layer on the substrate layer. The additive component travels along a preset path.

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