High-strength and high-toughness aluminum-erbium alloy wire suitable for electric arc additive manufacturing and preparation method of high-strength and high-toughness aluminum-erbium alloy wire

Abstract

The invention belongs to the technical field of aluminum alloy material manufacturing. The invention discloses a high-strength and high-toughness aluminum-erbium alloy wire suitable for electric arc additive manufacturing and a preparation method of the high-strength and high-toughness aluminum-erbium alloy wire. The alloy comprises 4.0-20.0 wt% of erbium (Er), 2.0-10.0 wt% of magnesium (Mg), smaller than or equal to 1.0 wt% of manganese (Mn) and the balance aluminum (Al). Optionally, from 0 to 1.0 wt% of scandium (Sc); optionally, from 0 to 1.0 wt% of zirconium (Zr). The welding wire is suitable for electric arc fuse wire additive manufacturing and aluminum magnesium alloy welding, particularly, a continuous cellular L12Al3Er eutectic network structure with the plastic deformation capacity is introduced, the size is in the hundred-nanometer magnitude, and strengthening and toughening are achieved. The aluminum-erbium alloy has excellent printing formability and comprehensive mechanical properties and can be widely applied to the fields of military industry and aerospace.

Description

Technical Field

[0001] The present invention belongs to the technical field of aluminum alloy material manufacturing, and in particular relates to a high-strength and high-toughness aluminum-erbium alloy wire suitable for arc additive manufacturing and a preparation method thereof. Background Art

[0002] As the parts in the aerospace and defense fields develop towards high performance, low cost, long life and light weight, typical special components are increasingly adopting integral structures, and parts tend to be lightweight and integrated. Wire arc additive manufacturing (WAAM) uses arc as a heat source to heat and melt metal wires, and continuously deposits them into shape. The thickness of the deposited layer can reach several millimeters. The equipment cost is low, and the material utilization rate is greater than 90%. It is suitable for the manufacture of large and medium-complex near-final components.

[0003] Although there have been many reports on aluminum alloy materials suitable for arc fuse additive manufacturing, their mechanical properties are still generally low, and many AlCu and AlZnMgCu system materials require "solid solution + aging" strengthening to achieve relatively high performance, which is obviously not suitable for large thin-walled parts; and although AlMg system materials do not need to undergo "solid solution + aging" strengthening, their mechanical properties are relatively low. Continuous innovation in the aerospace field requires aluminum alloy materials to continue to develop towards lightweight and high strengthening. Therefore, there is an urgent need for a high-performance additive manufacturing material that is not "solid solution + aging" strengthened. Summary of the invention

[0004] The purpose of the present invention is to provide an aluminum alloy wire material with high temperature, high strength and toughness suitable for arc fuse additive manufacturing process. The aluminum alloy wire material of the present invention has fine grains and uniform structure, and is suitable for arc fuse additive manufacturing. After heat treatment of the additive forming deposit, the grains are fine and uniform, the strengthening phase is dispersed, and it has high strength and toughness.

[0005] In one aspect, the present invention provides a high-strength and high-toughness aluminum alloy wire for arc additive manufacturing, wherein the aluminum alloy wire comprises:

[0006] 4.0-20.0wt% of erbium (Er), 2.0-10.0wt% of magnesium (Mg), and less than or equal to 1.0wt% of manganese (Mn);

[0007] Optionally, 0-1.0 wt% of scandium (Sc);

[0008] Optionally, 0-1.0 wt% zirconium (Zr);

[0009] The preparation method of the aluminum alloy wire comprises the following steps:

[0010] S1. Weigh pure metal or master alloy according to mass ratio and prepare the aluminum alloy powder by atomization powder making process;

[0011] S2, hot isostatic pressing the aluminum alloy powder to obtain an original rod blank;

[0012] S3, subjecting the ingot after the surface turning treatment of the original rod blank to an extrusion and diameter reduction treatment to obtain an extruded wire rod;

[0013] S4, subjecting the extruded wire rod to multiple drawing and annealing processes, and finally to scraping, sizing and ultrasonic cleaning to obtain an aluminum alloy wire.

[0014] In some embodiments, the aluminum alloy wire contains 4.0-20.0wt% erbium, for example, 4.0-7.0wt%, 4.0-8.0wt%, 4.0-9.0wt%, 4.0-10.0wt%, 4.0-11.0wt%, 4.0-12.0wt%, 4.0-15.0wt%, 5.0-20.0wt%, 5.0-15.0wt%, 5.0-12.0wt%, 5.0-11.0wt%, 7.0-20.0wt%, 7.0-15.0wt%, 7.0-12.0wt%, 7.0-11.0wt%, 9.0-20.0wt%, 9.0-15.0wt%, 9.0-12 ... .0-12.0wt%, 9.0-11.0wt%, 10.0-20.0wt%, 10.0-15.0wt%, 10.0-12.0wt% or 10.0-11.0wt%, and can further be 4.0wt%, 5.0wt%, 6.0wt%, 7.0wt%, 8.0wt%, 9.0wt%, 9.5%wt%, 10.0wt%, 10.8%wt%, 11.0wt%, 12.0wt%, 13.0wt%, 14.0wt%, 15.0wt%, 16.0wt%, 17.0wt%, 18.0wt%, 19.0wt%, 20.0wt% or a range between any two of the foregoing.

[0015] In some embodiments, the aluminum alloy wire contains 2.0-10.0wt% magnesium, for example, it can be 2.0-4.0wt%, 2.0-5.0wt%, 2.0-8.5wt%, 3.0-5.0wt%, 3.0-8.5wt%, 3.0-10.0wt%, 4.0-5.0wt%, 4.0-8.5wt% or 4.0-10.0wt%, and can further be 2.0wt%, 2.5wt%, 3.0wt%, 3.5wt%, 4.0wt%, 4.5wt%, 5.0wt%, 5.5wt%, 6.0wt%, 6.5wt%, 7.0wt%, 7.5wt%, 8.0wt%, 8.5wt%, 9.0wt%, 9.5wt%, 10.0wt% or a range between any two of the foregoing.

[0016] In some embodiments, the aluminum alloy wire contains less than or equal to 1.0wt% manganese, for example, less than or equal to 0.9wt%, less than or equal to 0.8wt%, less than or equal to 0.7wt%, less than or equal to 0.6wt%, less than or equal to 0.5wt%, less than or equal to 0.4wt%, less than or equal to 0.3wt%, less than or equal to 0.2wt%, less than or equal to 0.1wt%, and further can be 0.4-1.0wt%, 0.4-0.7wt%, 0.4-0.6wt%, 0.4-0.5wt%, 0.5-1.0wt%, 0. %, 0.5wt%, 0.6wt%, 0.7wt%, 0.8wt%, 0.85wt%, 0.9wt%, 0.95wt%, 1.0wt% or any range between any two of the foregoing.

[0017] In some optional embodiments, the aluminum alloy wire contains 0 - 1.0 wt% of scandium, for example, it can be 0 - 0.1 wt%, 0 - 0.5 wt%, 0.1 - 1.0 wt%, 0.1 - 0.5 wt%, 0.1 - 0.4 wt%, 0.1 - 0.3 wt%, 0.4 - 0.5 wt%, 0.4 - 1.0 wt% or 0.5 - 1.0 wt%. Further, it can be 0, 0.05 wt%, 0.1 wt%, 0.15 wt%, 0.2 wt%, 0.25 wt%, 0.3 wt%, 0.35 wt%, 0.4 wt%, 0.45 wt%, 0.5 wt%, 0.55 wt%, 0.6 wt%, 0.65 wt%, 0.7 wt%, 0.75 wt%, 0.8 wt%, 0.85 wt%, 0.9 wt%, 0.95 wt%, 1.0 wt% or the range between any two of the foregoing.

[0018] In some optional embodiments, the aluminum alloy wire contains 0 - 1.0 wt% of zirconium, for example, it can be 0 - 0.3 wt%, 0 - 0.4 wt%, 0 - 0.7 wt%, 0.1 - 0.3 wt%, 0.1 - 0.4 wt%, 0.1 - 0.7 wt%, 0.1 - 1.0 wt%, 0.3 - 0.4 wt%, 0.3 - 0.7 wt%, 0.3 - 1.0 wt%, 0.4 - 0.6 wt%, 0.4 - 0.7 wt% or 0.4 - 1.0 wt%. Further, it can be 0, 0.05 wt%, 0.1 wt%, 0.15 wt%, 0.2 wt%, 0.25 wt%, 0.3 wt%, 0.35 wt%, 0.4 wt%, 0.45 wt%, 0.5 wt%, 0.55 wt%, 0.6 wt%, 0.65 wt%, 0.7 wt%, 0.75 wt%, 0.8 wt%, 0.85 wt%, 0.9 wt%, 0.95 wt%, 1.0 wt% or the range between any two of the foregoing.

[0019] In some embodiments, the aluminum alloy wire contains 5.0 - 15.0 wt% of Er, preferably 9.0 - 12.0 wt%.

[0020] In some embodiments, the aluminum alloy wire contains 3.0 - 8.5 wt% of Mg, preferably 3.0 - 5.0 wt%.

[0021] In some embodiments, the aluminum alloy wire contains 0.4 - 0.7 wt% of Mn, preferably 0.5 - 0.6 wt%.

[0022] In some embodiments, the aluminum alloy wire contains 0 - 0.7 wt% of Zr, preferably 0.1 - 0.3 wt% or 0.4 - 0.6 wt%.

[0023] In some embodiments, the aluminum alloy wire comprises 0-0.5 wt % Sc, preferably 0.1-0.3 wt % or 0.4-0.5 wt %.

[0024] In some preferred embodiments, the aluminum alloy wire comprises 10.8 wt % Er, 4.5 wt % Mg, 0.6 wt % Mn, 0.5 wt % Sc, and 0.4 wt % Zr.

[0025] In some preferred embodiments, the aluminum alloy wire comprises 9.5 wt % Er, 3.5 wt % Mg, 0.6 wt % Mn, 0.5 wt % Sc, and 0.3 wt % Zr.

[0026] In some preferred embodiments, the aluminum alloy wire comprises 7.0 wt % Er, 4.5 wt % Mg, 0.5 wt % Mn, 0.1 wt % Sc, and 0.3 wt % Zr.

[0027] In some embodiments, the aluminum alloy wire includes aluminum and inevitable impurities as the balance.

[0028] In some embodiments, the impurity element includes at least one of iron, titanium, boron, silicon, chromium, vanadium, zinc, phosphorus, calcium, nickel, copper, lanthanum, cerium, or lithium.

[0029] In some embodiments, the aluminum alloy wire exhibits a dual grain morphology in which columnar crystals and equiaxed crystals coexist.

[0030] In some embodiments, the columnar crystals contain continuous Al 3 Er cellular eutectic network structure.

[0031] In some embodiments, in the network structure, the network unit size is 300-400 nm, for example, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390 or 400 nm, preferably 320-380 nm.

[0032] In some embodiments, the Al 3 The Er cellular eutectic network structure contains twin structures.

[0033] In some embodiments, the aluminum alloy wire has a diameter of 0.8-5.0 mm, for example, 0.8, 0.9, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5 or 5.0 mm, preferably 0.8-3.0 mm.

[0034] In some embodiments, the atomization powder making process in step S1 includes one or more selected from gas atomization, rotary electrode atomization and ultrasonic atomization;

[0035] In some embodiments, the hot isostatic pressing temperature in step S2 is 450-550°C, for example, it can be 450°C, 455°C, 460°C, 465°C, 470°C, 475°C, 480°C, 485°C, 490°C, 495°C, 500°C, 505°C, 510°C, 515°C, 520°C, 525°C, 530°C, 535°C, 540°C, 545°C or 550°C, preferably 500-520°C, more preferably 510°C.

[0036] In some embodiments, the argon pressure of the hot isostatic pressing treatment in step S2 is 75-150 MPa, for example, it can be 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145 or 150 MPa, preferably 80-100 MPa, and more preferably 90-95 MPa.

[0037] In some embodiments, the thickness removed by the surface turning treatment in step S3 is 5-15% of the thickness of the original rod blank, for example, it can be 5%, 5.5%, 6%, 6.5%, 7%, 7.5%, 8%, 8.5%, 9%, 9.5%, 10%, 10.5%, 11%, 11.5%, 12%, 12.5%, 13%, 13.5%, 14%, 14.5% or 15%, preferably 5-10%.

[0038] In some embodiments, the primary extrusion in step S3 is performed after the ingot after the surface turning treatment is kept warm.

[0039] In some embodiments, the insulation temperature is 450-550°C, for example, it can be 450°C, 455°C, 460°C, 465°C, 470°C, 475°C, 480°C, 485°C, 490°C, 495°C, 500°C, 505°C, 510°C, 515°C, 520°C, 525°C, 530°C, 535°C, 540°C, 545°C or 550°C, preferably 500-520°C, more preferably 505-515°C.

[0040] In some embodiments, the insulation time is 10-20 hours, for example, it can be 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 hours, preferably 10-15 hours, and more preferably 12 hours.

[0041] In some embodiments, the temperature of the round rod at the extrusion outlet in step S3 is 420-480°C, for example, it can be 420°C, 425°C, 430°C, 435°C, 440°C, 445°C, 450°C, 455°C, 460°C, 465°C, 470°C, 475°C or 480°C, preferably 450-480°C, more preferably 460-480°C.

[0042] In some embodiments, the diameter of the extruded wire rod in step S3 is 3-6% of the once extruded turned round rod, for example, it can be 3%, 3.5%, 4%, 4.5%, 5%, 5.5% or 6%, preferably 4-6%.

[0043] In some embodiments, the extrusion ratio of the extrusion in step S3 is (35-75):1, for example, it can be 35:1, 40:1, 45:1, 50:1, 55:1, 60:1, 65:1, 70:1 or 75:1, preferably (45-55):1, and more preferably 50:1.

[0044] In some embodiments, annealing is performed once per drawing pass in step S4, and the total number of annealing is not less than 10 times.

[0045] In some embodiments, the annealing temperature in step S4 is 500-550°C, for example, it can be 500°C, 505°C, 510°C, 515°C, 520°C, 525°C, 530°C, 535°C, 540°C, 545°C or 550°C, preferably 510-530°C, more preferably 515-520°C.

[0046] On the other hand, the present invention provides use of the aluminum alloy wire in aluminum-magnesium alloy welding.

[0047] In another aspect, the present invention provides an aluminum alloy block prepared by arc additive manufacturing of the above-mentioned aluminum alloy wire.

[0048] In some embodiments, the arc additive mode is CMT (cold metal transfer technology) direct current.

[0049] In some embodiments, the arc additive wire feeding speed is 4-8 m / min, for example, it can be 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5 or 8 m / min, preferably 5-6 m / min.

[0050] In some embodiments, the arc additive current is 70-100A, for example, 70, 75, 78, 80, 85, 90, 95 or 100A, preferably 75-90A.

[0051] In some embodiments, the arc additive voltage is 10-15V, for example, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.2, 13.5, 14, 14.5 or 15V, preferably 12-14V.

[0052] In some embodiments, the arc additive speed is 40-60 cm / min, for example, 40, 42, 44, 46, 48, 50, 52, 54, 56, 58 or 60 cm / min, preferably 50 cm / min.

[0053] In some embodiments, the arc additive layer residence time is 120-180 s, for example, it can be 120, 130, 140, 150, 160, 170 or 180 s, preferably 150 s.

[0054] In some embodiments, the aluminum alloy block is further subjected to aging heat treatment.

[0055] In some embodiments, the temperature of the aging heat treatment is 200-400°C, for example, it can be 200°C, 210°C, 220°C, 230°C, 240°C, 250°C, 260°C, 270°C, 280°C, 290°C, 300°C, 310°C, 320°C, 330°C, 340°C, 350°C, 360°C, 370°C, 380°C, 390°C or 400°C, preferably 300°C.

[0056] In some embodiments, the aging heat treatment time is 4-8 hours, for example, it can be 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5 or 8 hours, preferably 4-6 hours.

[0057] In some embodiments, the aluminum alloy block has an aging tensile strength of not less than 580 MPa, for example, not less than 585 MPa, not less than 590 MPa, not less than 595 MPa or not less than 600 MPa. In some preferred embodiments, the aging tensile strength is not less than 600 MPa.

[0058] In some embodiments, the aged tensile strength is 580-620 MPa, for example, it can be 580-590 MPa, 580-600 MPa, 580-610 MPa, 585-590 MPa, 585-600 MPa, 585-610 MPa, 585-620 MPa, 590-610 MPa, 590-620 MPa, 600-610 MPa or 600-620 MPa, and can further be 580, 585, 589, 590, 595, 600, 602, 605, 610, 615 or 620 MPa.

[0059] In some embodiments, the aluminum alloy block has an aging state yield strength of not less than 480 MPa, for example, not less than 480 MPa, not less than 490 MPa, not less than 500 MPa, not less than 505 MPa or not less than 510 MPa. In some preferred embodiments, the aging state yield strength is not less than 500 MPa.

[0060] In some embodiments, the aged yield strength is 480-550 MPa, for example, it can be 480-510 MPa, 480-520 MPa, 500-520 MPa, 500-550 MPa, 510-520 MPa or 510-550 MPa, and can further be 480, 485, 490, 495, 500, 505, 510, 512, 515, 520, 525, 530, 535, 540, 545 or 550 MPa.

[0061] In some embodiments, the aluminum alloy block has an aging elongation of not less than 6%, for example, not less than 7%, not less than 8%, not less than 9% or not less than 10%. In some preferred embodiments, the aging elongation is not less than 7%.

[0062] In some embodiments, the aged elongation is 6%-12%, for example, it can be 6%-8%, 6%-9%, 6%-11%, 7%-11%, 8%-11%, 7%-9%, 7%-8%, 7%-12% or 8%-12%, and can further be 6%, 6.5%, 7%, 7.5%, 8%, 8.5%, 8.8%, 9%, 9.5%, 10%, 10.5%, 10.6%, 11%, 11.5% or 12%.

[0063] In yet another aspect, the present invention provides an aluminum alloy component, wherein at least a portion of the aluminum alloy component comprises the above-mentioned aluminum alloy wire or the above-mentioned aluminum alloy block.

[0064] In some embodiments, the aluminum alloy component is used to prepare military equipment or aerospace equipment.

[0065] Advantages of the invention

[0066] 1. The aluminum alloy wire of the present invention has excellent printability. Based on the Al-Er eutectic system, it has a small solidification range and a low tendency to thermal cracking. In addition, unlike other eutectic aluminum alloy systems, additional Al can be formed during the solidification process. 3 The Er primary phase is coherent with the aluminum matrix and thus plays a role in grain refinement, further improving the solidification behavior and thermal cracking sensitivity of the Al-Er system.

[0067] 2. The block material formed by the aluminum alloy wire WAAM of the present invention has outstanding mechanical properties. The yield strength in the printed state can be greater than 410MPa, the tensile strength can be greater than 500MPa, and the elongation can be greater than 10%; after simple aging heat treatment, the yield strength in the aged state can be greater than 480MPa, the tensile strength can be greater than 580MPa, and the elongation can be greater than 6%. The yield strength in the printed state exceeds the level of all currently WAAM-made ultra-high-strength aluminum alloys.

[0068] 3. Al in the bulk material of the aluminum alloy wire WAAM of the present invention 3 The Er eutectic phase forms a continuous cellular network structure with significant strengthening effect.

[0069] 4. Al in the bulk material of the aluminum alloy wire WAAM of the present invention 3 The Er eutectic phase contains a large number of nanotwins, indicating that the eutectic phase (and its cellular network structure) has the ability of plastic deformation, which ensures the strong plastic matching of the material. The emergence of nanotwins will also enhance the strength of the eutectic network structure, thereby improving the overall strength level of the material. 3 The Er eutectic phase is coherent with the aluminum matrix, which is conducive to the coordinated deformation between the two.

[0070] 5. The high-strength aluminum alloy wire of the present invention is highly applicable to additive manufacturing processes such as WAAM and can be used for large-scale industrial production. DETAILED DESCRIPTION

[0071] For the purpose of clear and concise description, features are described herein as part of some identical or separate embodiments, however, it will be understood that the scope of the present disclosure may include some embodiments having a combination of all or some of the described features. The technical solution of the present invention will be clearly and completely described below. Obviously, based on the specific embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0072] I. Definitions

[0073] In the present invention, unless otherwise specified, the scientific and technical terms used herein have the meanings commonly understood by those skilled in the art. In addition, the relevant terms and laboratory procedures used herein are terms and conventional procedures widely used in the corresponding fields. At the same time, in order to better understand the present invention, the definitions and explanations of the relevant terms are provided below.

[0074] As used herein and unless otherwise specified, the term "about" or "approximately" means within plus or minus 10% of a given value or range. Where an integer is required, the term means within plus or minus 10% of a given value or range, rounded up or down to the nearest integer.

[0075] In the description of this document, reference is made to “some embodiments”, “some implementation schemes” or “some implementation plans”, which describe a subset of all possible embodiments, but it can be understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict.

[0076] As used herein and unless otherwise specified, the terms "comprising", "including", "having", "containing", including grammatical equivalents thereof, should generally be understood as open and non-limiting, for example, not excluding other unlisted elements or steps.

[0077] As used herein, the term "wt%" refers to the weight ratio and the proportion of a substance in a mixture. For example, 2.0-10.0 wt% of magnesium (Mg) means that the weight proportion of Mg in the total weight of all elements in the alloy is 2.0-10.0 wt%.

[0078] As used herein, the term "aluminum alloy" refers to an alloy having aluminum as the base and a certain amount of other alloying elements added thereto.

[0079] As used herein, the term "nominal composition" refers to the weight proportion of each metal element input into the raw material in the total raw material.

[0080] As used herein, the term "additive manufacturing" refers to any process that produces a three-dimensional object and includes steps of sequentially forming the shape of one layer of the object at a time. For example, AM processes include three-dimensional printing (3DP) processes, laser net shaping manufacturing, direct metal laser sintering (DMLS), direct metal laser melting (DMLM), laser powder bed fusion process (LPBF), arc additive manufacturing (WAAM), free-form manufacturing, etc. AM processes can use metal powder materials or wires as raw materials. Additive manufacturing is a method of manufacturing physical objects from digital objects by adding materials layer by layer, and the thickness of each added layer is about tens or hundreds of microns. "Arc additive manufacturing" refers to using wire as raw material, and stacking the wire layer by layer through an electric arc to form a three-dimensional solid metal component.

[0081] II. Examples

[0082] The present invention is described in detail below through specific examples. It should be understood that the following examples are only for explanation and illustration and are not intended to limit the scope of the present invention in any form.

[0083] The raw materials and equipment used in the specific embodiments of the present disclosure are all known products, which are obtained by purchasing commercially available products.

[0084] The alloy element analysis disclosed in the present invention is measured by inductively coupled plasma emission spectrometry, and the weight percentage of the elements is calculated based on the measurement results.

[0085] Yield strength, tensile strength and elongation were measured according to ASTM E8 / E8M-15a standard method.

[0086] Example 1

[0087] Preparation of wire with Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr as the nominal composition, the weight proportion of each element in the powder form alloy product is: Er 10.8%, Mg 4.5%, Mn 0.6%, Sc 0.5%, Zr 0.4%, the balance is Al and unavoidable impurities, the preparation steps are as follows:

[0088] (1) Raw material preparation:

[0089] 13.25 kg of pure Al, 2.25 kg of pure Mg, 27 kg of Al-20Er master alloy block, 3 kg of Al-10Mn master alloy block, 2.50 kg of Al-10Sc master alloy block, and 2 kg of Al-10Zr master alloy block were weighed as raw materials respectively, and according to the standard of Mg, Sc, and Zr recovery rate of 95%, 0.12 kg of pure Mg, 0.13 kg of Al-10Sc master alloy block, and 0.10 kg of Al-10Zr master alloy block were additionally weighed as the raw material part for burning loss;

[0090] (2) Melting of Al-Er-Mg-Mn-Sc-Zr alloy prefabricated ingot:

[0091] a. Mix pure Al, pure Mg, and Al-20Er master alloy blocks into a graphite crucible, heat to 780°C in a resistance furnace to melt, and stir with a graphite stirring rod for 3 minutes;

[0092] b. Add Al-Mn master alloy block, Al-Zr master alloy block, Al-Sc master alloy block to the melt and stir with a graphite stirring rod for 3 minutes;

[0093] c. Add pure Mg into the melt and use a graphite rod to press it into the bottom of the melt to dissolve;

[0094] d. Add refining agent for refining, then scrape off the surface slag, sprinkle covering agent, and vacuum degas for 10 minutes;

[0095] e. Remove the surface slag and cast it into a cylindrical mold preheated at 250°C to obtain a cylindrical ingot;

[0096] f. Use mechanical processing methods to remove the oxide scale on the surface of the ingot.

[0097] (3) Gas atomization forming of Al-Er-Mg-Mn-Sc-Zr alloy powder:

[0098] a. placing the Al-Er-Mg-Mn-Sc-Zr prefabricated ingot in a graphite crucible in a smelting chamber, closing the chamber door, reducing the vacuum degree in the smelting chamber through a vacuum system, and then introducing nitrogen into the chamber to further replace the air in the chamber and reduce the oxygen content in the chamber;

[0099] b. Heating the cavity by electromagnetic induction, with a target temperature of 800°C and keeping it warm for 0.5h to completely melt the ingot;

[0100] c. The molten melt flows along the nozzle under the action of gravity and is broken into droplets of different sizes under the impact of the fast-moving atomized argon gas. The droplets solidify into powder during the falling process, and the falling powder is collected at the bottom of the cavity;

[0101] d. The collected powder is vacuum packed to prevent the powder from being oxidized.

[0102] The composition of the Al-Er-Mg-Mn-Sc-Zr powder obtained in this embodiment was obtained by inductively coupled plasma emission spectrometry and was Al-10.8Er-4.5Mg-0.6Mn-0.5Sc-0.4Zr, which was consistent with the designed nominal composition value.

[0103] (4) Hot isostatic pressing of Al-Er-Mg-Mn-Sc-Zr alloy powder:

[0104] a. The Al-Er-Mg-Mn-Sc-Zr powder is placed in an aluminum jacket prefabricated container, the jacket diameter being 120 mm;

[0105] b. Seal the filled high-pressure resistant aluminum sleeve to prevent powder leakage under high pressure;

[0106] c. Place the sealed mold into a hot isostatic press;

[0107] d. Maintain the pressure for 3 hours at a heating rate of 5°C / min, a target temperature of 510°C, and an argon pressure of 95 MPa to ensure powder sintering and isostatic pressing;

[0108] e. After processing, it is cooled and then the original rod embryo is taken out.

[0109] (5) Hot extrusion treatment of Al-Er-Mg-Mn-Sc-Zr alloy:

[0110] a. Turn the original rod blank after hot isostatic pressing to an outer diameter of 115 mm;

[0111] b. Put the turned rod blank into the extruder for one extrusion, with the holding temperature at 515℃, and keep the ingot warm for 12 hours before extrusion. The extrusion ratio is set to 50:1, and the temperature of the round rod at the extrusion outlet is 480℃. Obtain an extruded wire rod with a diameter of 8.0mm.

[0112] (6) Al-Er-Mg-Mn-Sc-Zr alloy wire:

[0113] a. Connect the 8.0mm diameter extruded wire rod and put it into the wire drawing machine for drawing. When drawing from 8.0mm diameter to 5.6mm diameter, annealing is performed for each drawing, and the diameter is reduced by 0.6mm each time. The annealing temperature is 520℃ and the temperature is kept for 6 hours. When drawing from 5.6mm diameter to 2.5mm diameter, annealing is performed for each drawing, and the diameter is reduced by 0.5mm each time. The annealing temperature is 520℃ and the temperature is kept for 6 hours. When drawing from 2.5mm diameter to 1.54mm diameter, annealing is performed for each drawing, and the diameter is reduced by 0.2mm each time. The annealing temperature is 520℃ and the temperature is kept for 4 hours.

[0114] The aluminum alloy wire obtained in Example 1 was subjected to arc additive manufacturing (WAAM), and the process parameters are as follows:

[0115] Table 1 Arc additive process parameters

[0116] model Wire feeding speed Current Voltage Additive speed Interlayer residence time CMT DC 5m / min 78A 12.5V 50cm / min 150s

[0117] The arc additively manufactured samples were subjected to aging heat treatment at 300°C for 6 hours and their mechanical properties were tested. The test results showed that the yield strength was 515 MPa, the tensile strength was 602 MPa, and the test elongation was 7.5%.

[0118] Example 2

[0119] Prepare Al-9.5Er-3.5Mg-0.6Mn-0.5Sc-0.3Zr as the nominal composition of the wire, the weight proportion of each element in the powder form alloy product is: Er 9.5%, Mg 3.5%, Mn 0.6%, Sc 0.5%, Zr 0.4%, the balance is Al and unavoidable impurities, the preparation steps are as follows:

[0120] (1) Raw material preparation:

[0121] 17.50 kg of pure Al, 1.75 kg of pure Mg, 23.75 kg of Al-20Er master alloy block, 3 kg of Al-10Mn master alloy block, 2.50 kg of Al-10Sc master alloy block, and 1.5 kg of Al-10Zr master alloy block were weighed as raw materials respectively, and according to the standard that the recovery rate of Mg, Sc, and Zr is 95%, 0.10 kg of pure Mg, 0.10 kg of Al-10Sc master alloy block, and 0.10 kg of Al-10Zr master alloy block were additionally weighed as the raw material part for burning loss;

[0122] (2) Melting of Al-Er-Mg-Mn-Sc-Zr alloy prefabricated ingot:

[0123] a. Mix pure Al, pure Mg, and Al-20Er master alloy blocks into a graphite crucible, heat to 780°C in a resistance furnace to melt, and stir with a graphite stirring rod for 3 minutes;

[0124] b. Add Al-Mn master alloy block, Al-Zr master alloy block, Al-Sc master alloy block to the melt and stir with a graphite stirring rod for 3 minutes;

[0125] c. Add pure Mg into the melt and use a graphite rod to press it into the bottom of the melt to dissolve;

[0126] d. Add refining agent for refining, then scrape off the surface slag, sprinkle covering agent, and vacuum degas for 10 minutes;

[0127] e. Remove the surface slag and cast it into a cylindrical mold preheated at 250°C to obtain a cylindrical ingot;

[0128] f. Use mechanical processing methods to remove the oxide scale on the surface of the ingot.

[0129] (3) Gas atomization forming of Al-Er-Mg-Mn-Sc-Zr alloy powder:

[0130] a. placing the Al-Er-Mg-Mn-Sc-Zr prefabricated ingot in a graphite crucible in a smelting chamber, closing the chamber door, reducing the vacuum degree in the smelting chamber through a vacuum system, and then introducing nitrogen into the chamber to further replace the air in the chamber and reduce the oxygen content in the chamber;

[0131] b. Heating the cavity by electromagnetic induction, with a target temperature of 800°C and keeping it warm for 0.5h to completely melt the ingot;

[0132] c. The molten melt flows along the nozzle under the action of gravity and is broken into droplets of different sizes under the impact of the fast-moving atomized argon gas. The droplets solidify into powder during the falling process, and the falling powder is collected at the bottom of the cavity;

[0133] d. The collected powder is vacuum packed to prevent the powder from being oxidized.

[0134] The composition of the Al-Er-Mg-Mn-Sc-Zr powder obtained in this embodiment was obtained by inductively coupled plasma emission spectrometry and was Al-9.5Er-3.5Mg-0.6Mn-0.5Sc-0.3Zr, which was consistent with the designed nominal composition value.

[0135] (4) Hot isostatic pressing of Al-Er-Mg-Mn-Sc-Zr alloy powder:

[0136] a. The Al-Er-Mg-Mn-Sc-Zr powder is placed in an aluminum jacket prefabricated container, the jacket diameter being 120 mm;

[0137] b. Seal the filled high-pressure resistant aluminum sleeve to prevent powder leakage under high pressure;

[0138] c. Place the sealed mold into a hot isostatic press;

[0139] d. Maintain the pressure for 3 hours at a heating rate of 5°C / min, a target temperature of 510°C, and an argon pressure of 90 MPa to ensure powder sintering and isostatic pressing;

[0140] e. After processing, it is cooled and then the original rod embryo is taken out.

[0141] (5) Hot extrusion treatment of Al-Er-Mg-Mn-Sc-Zr alloy:

[0142] a. Turn the original rod blank after hot isostatic pressing to an outer diameter of 115 mm;

[0143] b. Put the turned rod blank into the extruder for one extrusion, with the holding temperature at 505℃ and the ingot kept warm for 12 hours before extrusion. The extrusion ratio is set to 50:1, and the temperature of the round rod at the extrusion outlet is 460℃. The extruded wire rod with a diameter of 8.0mm is obtained.

[0144] (6) Al-Er-Mg-Mn-Sc-Zr alloy wire:

[0145] a. Connect the 8.0mm diameter extruded wire rod and put it into the wire drawing machine for drawing. When drawing from 8.0mm diameter to 5.6mm diameter, annealing is performed every time when drawing, and the diameter is reduced by 0.6mm every time. The annealing temperature is 515℃ and the temperature is kept for 6 hours. When drawing from 5.6mm diameter to 2.5mm diameter, annealing is performed every time when drawing, and the diameter is reduced by 0.5mm every time. The annealing temperature is 515℃ and the temperature is kept for 6 hours. When drawing from 2.5mm diameter to 1.54mm diameter, annealing is performed every time when drawing, and the diameter is reduced by 0.2mm every time. The annealing temperature is 515℃ and the temperature is kept for 4 hours.

[0146] The aluminum alloy wire obtained in Example 2 was subjected to arc additive manufacturing (WAAM), and the process parameters are as follows:

[0147] Table 2 Arc additive process parameters

[0148] model Wire feeding speed Current Voltage Additive speed Interlayer residence time CMT DC 5m / min 75A 12.5V 50cm / min 120s

[0149] The arc additively manufactured samples were subjected to aging heat treatment at 300°C for 4 hours and their mechanical properties were tested. The test results showed that the yield strength was 505 MPa, the tensile strength was 589 MPa, and the test elongation was 8.8%.

[0150] Example 3

[0151] Prepare Al-7Er-4.5Mg-0.5Mn-0.1Sc-0.3Zr as the nominal composition of the wire, the weight proportion of each element in the powder form alloy product is: Er 7%, Mg 4.5%, Mn 0.5%, Sc 0.1%, Zr 0.3%, the balance is Al and unavoidable impurities, the preparation steps are as follows:

[0152] (1) Raw material preparation:

[0153] 23.75 kg of pure Al, 2.25 kg of pure Mg, 17.5 kg of Al-20Er master alloy block, 2.5 kg of Al-10Mn master alloy block, 2.50 kg of Al-2Sc master alloy block, and 1.5 kg of Al-10Zr master alloy block were weighed as raw materials respectively, and according to the standard of Mg, Sc, and Zr recovery rate of 95%, 0.12 kg of pure Mg, 0.25 kg of Al-2Sc master alloy block, and 0.10 kg of Al-10Zr master alloy block were additionally weighed as raw materials to supplement the burn-out;

[0154] (2) Melting of Al-Er-Mg-Mn-Sc-Zr alloy prefabricated ingot:

[0155] a. Mix pure Al, pure Mg, and Al-20Er master alloy blocks into a graphite crucible, heat to 780°C in a resistance furnace to melt, and stir with a graphite stirring rod for 3 minutes;

[0156] b. Add Al-Mn master alloy block, Al-Zr master alloy block, Al-Sc master alloy block to the melt and stir with a graphite stirring rod for 3 minutes;

[0157] c. Add pure Mg into the melt and use a graphite rod to press it into the bottom of the melt to dissolve;

[0158] d. Add refining agent for refining, then scrape off the surface slag, sprinkle covering agent, and vacuum degas for 10 minutes;

[0159] e. Remove the surface slag and cast it into a cylindrical mold preheated at 250°C to obtain a cylindrical ingot;

[0160] f. Use mechanical processing methods to remove the oxide scale on the surface of the ingot.

[0161] (3) Gas atomization forming of Al-Er-Mg-Mn-Sc-Zr alloy powder:

[0162] a. placing the Al-Er-Mg-Mn-Sc-Zr prefabricated ingot in a graphite crucible in a smelting chamber, closing the chamber door, reducing the vacuum degree in the smelting chamber through a vacuum system, and then introducing nitrogen into the chamber to further replace the air in the chamber and reduce the oxygen content in the chamber;

[0163] b. Heating the cavity by electromagnetic induction, with a target temperature of 800°C and keeping it warm for 0.5h to completely melt the ingot;

[0164] c. The molten melt flows along the nozzle under the action of gravity and is broken into droplets of different sizes under the impact of the fast-moving atomized argon gas. The droplets solidify into powder during the falling process, and the falling powder is collected at the bottom of the cavity;

[0165] d. The collected powder is vacuum packed to prevent the powder from being oxidized.

[0166] The composition of the Al-Er-Mg-Mn-Sc-Zr powder obtained in this embodiment was obtained by inductively coupled plasma emission spectrometry and was Al-7Er-4.5Mg-0.5Mn-0.1Sc-0.3Zr, which was consistent with the designed nominal composition value.

[0167] (4) Hot isostatic pressing of Al-Er-Mg-Mn-Sc-Zr alloy powder:

[0168] a. The Al-Er-Mg-Mn-Sc-Zr powder is placed in an aluminum jacket prefabricated container, the jacket diameter being 120 mm;

[0169] b. Seal the filled high-pressure resistant aluminum sleeve to prevent powder leakage under high pressure;

[0170] c. Place the sealed mold into a hot isostatic press;

[0171] d. Maintain the pressure for 3 hours at a heating rate of 5°C / min, a target temperature of 510°C, and an argon pressure of 90 MPa to ensure powder sintering and isostatic pressing;

[0172] e. After processing, it is cooled and then the original rod embryo is taken out.

[0173] (5) Hot extrusion treatment of Al-Er-Mg-Mn-Sc-Zr alloy:

[0174] a. Turn the original rod blank after hot isostatic pressing to an outer diameter of 115 mm;

[0175] b. Put the turned rod blank into the extruder for one extrusion, the holding temperature is 510℃, and the ingot is kept warm for 12 hours before extrusion. The extrusion ratio is set to 50:1, and the extrusion outlet round rod temperature is 470℃. Obtain an extruded wire rod with a diameter of 8.0mm.

[0176] (6) Al-Er-Mg-Mn-Sc-Zr alloy wire:

[0177] a. Connect the 8.0mm diameter extruded wire rod and put it into the wire drawing machine for drawing. When drawing from 8.0mm diameter to 5.6mm diameter, annealing is performed for each drawing, and the diameter is reduced by 0.6mm each time. The annealing temperature is 520℃ and the temperature is kept for 6 hours. When drawing from 5.6mm diameter to 2.5mm diameter, annealing is performed for each drawing, and the diameter is reduced by 0.5mm each time. The annealing temperature is 520℃ and the temperature is kept for 6 hours. When drawing from 2.5mm diameter to 1.54mm diameter, annealing is performed for each drawing, and the diameter is reduced by 0.2mm each time. The annealing temperature is 520℃ and the temperature is kept for 4 hours.

[0178] The aluminum alloy wire obtained in Example 3 was subjected to arc additive manufacturing (WAAM), and the process parameters are as follows:

[0179] Table 3 Arc additive process parameters

[0180] model Wire feeding speed Current Voltage Additive speed Interlayer residence time CMT DC 6m / min 90A 13.2V 50cm / min 150s

[0181] The arc additively manufactured samples were subjected to aging heat treatment at 300°C for 6 hours and their mechanical properties were tested. The test results showed that the yield strength was 512 MPa, the tensile strength was 585 MPa, and the test elongation was 10.6%.

[0182] It should be noted that, under the composition formula defined in the present invention, aluminum alloy wires with excellent performance can be obtained, and therefore the preparation method described in the present invention is not limited thereto.

[0183] The specific embodiments of the present invention are described in detail above, but they are only examples, and the present invention is not limited to the specific embodiments described above. For those skilled in the art, any equivalent modifications and substitutions made to the present invention are also within the scope of the present invention. Therefore, the equalization changes and modifications made without departing from the spirit and scope of the present invention are all within the scope of the present invention.

Claims

1. A high-strength and high-toughness aluminum alloy wire for arc additive manufacturing, wherein: The aluminum alloy wire comprises: 4.0-20.0wt% of erbium (Er), 2.0-10.0wt% of magnesium (Mg), and less than or equal to 1.0wt% of manganese (Mn); Optionally, 0-1.0 wt% of scandium (Sc); Optionally, 0-1.0 wt% zirconium (Zr); The preparation method of the aluminum alloy wire comprises the following steps: S1. Weigh pure metal or master alloy according to mass ratio and prepare the aluminum alloy powder by atomization powder making process; S2, hot isostatic pressing the aluminum alloy powder to obtain an original rod blank; S3, subjecting the ingot after the surface turning treatment of the original rod blank to an extrusion and diameter reduction treatment to obtain an extruded wire rod; S4, subjecting the extruded wire rod to multiple drawing and annealing processes, and finally to scraping, sizing and ultrasonic cleaning to obtain an aluminum alloy wire.

2. The aluminum alloy wire according to claim 1, wherein The aluminum alloy wire contains 5.0-15.0wt% Er, preferably 9.0-12.0wt%; Preferably, the aluminum alloy wire contains 3.0-8.5wt% Mg, preferably 3.0-5.0wt%; Preferably, the aluminum alloy wire contains 0.4-0.7wt% Mn, preferably 0.5-0.6wt%; Preferably, the aluminum alloy wire contains 0-0.7wt% Zr, preferably 0.1-0.3wt% or 0.4-0.6wt%; Preferably, the aluminum alloy wire contains 0-0.5wt% Sc, preferably 0.1-0.3wt% or 0.4-0.5wt%; More preferably, the aluminum alloy wire comprises: 10.8wt% Er, 4.5wt% Mg, 0.6wt% Mn, 0.5wt% Sc, 0.4wt% Zr; or, 9.5wt% Er, 3.5wt% Mg, 0.6wt% Mn, 0.5wt% Sc, 0.3wt% Zr; or, 7.0wt% Er, 4.5wt% Mg, 0.5wt% Mn, 0.1wt% Sc, 0.3wt% Zr.

3. The aluminum alloy wire according to claim 1 or 2, wherein: The aluminum alloy wire contains aluminum and inevitable impurities as the balance; Preferably, the impurity element includes at least one of iron, titanium, boron, silicon, chromium, vanadium, zinc, phosphorus, calcium, nickel, copper, lanthanum, cerium or lithium.

4. The aluminum alloy wire according to any one of claims 1 to 3, wherein: The aluminum alloy wire material presents a double grain morphology in which columnar crystals and equiaxed crystals coexist.

5. The aluminum alloy wire according to claim 4, wherein: The columnar crystals contain a continuous Al3Er cellular eutectic network structure; Preferably, in the network structure, the network unit size is 300-400nm, preferably 320-380nm; Preferably, the Al3Er cellular eutectic network structure contains a twin structure.

6. The aluminum alloy wire according to claim 1, wherein: The diameter of the aluminum alloy wire is 0.8-5.0 mm, preferably 0.8-3.0 mm; Preferably, the atomization powder making process in step S1 includes one or more selected from gas atomization, rotary electrode atomization and ultrasonic atomization; Preferably, the hot isostatic pressing treatment temperature in step S2 is 450-550°C, preferably 500-520°C; Preferably, the argon pressure of the hot isostatic pressing treatment in step S2 is 75-150 MPa, preferably 80-100 MPa, more preferably 90-95 MPa; Preferably, the thickness removed by the surface turning process in step S3 is 5-15%, preferably 5-10% of the thickness of the original rod blank; Preferably, the first extrusion in step S3 is performed after the ingot after the surface turning treatment is kept warm; Preferably, the insulation temperature is 450-550°C, preferably 500-520°C, more preferably 505-515°C; Preferably, the insulation time is 10-20 hours, preferably 10-15 hours; Preferably, the temperature of the round bar at the extrusion outlet in step S3 is 420-480°C, preferably 450-480°C, more preferably 460-480°C; Preferably, the diameter of the extruded wire rod in step S3 is 3-6%, preferably 4-6% of the once extruded turned round rod; Preferably, the extrusion ratio of the extrusion in step S3 is (35-75):1, preferably (45-55):1; Preferably, in step S4, annealing is performed once for each drawing pass, and the total number of annealing is not less than 10 times; Preferably, the annealing temperature in step S4 is 500-550°C, preferably 510-530°C, more preferably 515-520°C.

7. Use of the aluminum alloy wire according to any one of claims 1 to 6 in aluminum-magnesium alloy welding.

8. Aluminum alloy block prepared by arc additive manufacturing of the aluminum alloy wire according to any one of claims 1 to 6; Preferably, the aluminum alloy block is further subjected to aging heat treatment; Preferably, the temperature of the aging heat treatment is 200-400°C, preferably 300°C; Preferably, the aging heat treatment time is 4-8 hours, preferably 4-6 hours.

9. The aluminum alloy block according to claim 8, wherein: The aluminum alloy block meets at least one of the following conditions: (1) The tensile strength in the aged state is not less than 580 MPa; (2) The aging yield strength is not less than 480 MPa; (3) The elongation in the aging state is not less than 6%; Preferably, the aged tensile strength is not less than 600 MPa; Preferably, the aged tensile strength is 580-620 MPa; Preferably, the aging state yield strength is not less than 500MPa; Preferably, the aging state yield strength is 480-550MPa; Preferably, the elongation in the aging state is not less than 7%; Preferably, the elongation in the aged state is 6%-12%.

10. An aluminum alloy component, wherein: At least a portion of the aluminum alloy component comprises the aluminum alloy wire material according to any one of claims 1 to 6 or the aluminum alloy block material according to claim 8 or 9; Preferably, the aluminum alloy component is used to prepare military equipment or aerospace equipment.