Method for preparing metal component through arc fuse wire additive manufacturing and needle-free friction stir compounding

Abstract

The invention provides a method for preparing a metal component through arc fuse wire additive manufacturing and needle-free stirring friction compositing, an arc fuse wire additive manufacturing process is adopted, layer-by-layer deposition is carried out on a substrate from a first layer in an upward growth mode according to a preset printing program until the last layer is deposited, and the needed metal component is obtained; wherein in the deposition process from the first layer to the last layer, each deposition layer is treated through needleless stirring friction, the surface finishing degree of the current deposition layer is improved, an oxide layer on the surface of the deposition layer is eliminated, and the mutual fusion degree between the next deposition layer and the current deposition layer is deepened; and meanwhile, the residual stress of the current deposition layer is redistributed and segregation is eliminated through needle-free stirring friction, so that the interlayer bonding property between the adjacent deposition layers is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of metal additive manufacturing, and in particular to a method for preparing metal components by arc wire additive manufacturing combined with non - needle friction stir welding. Background Art

[0002] Aluminum alloys have the characteristics of high specific strength, light weight, and good corrosion resistance, and have broad application prospects in many fields as high - strength structural materials. However, due to the good electrical and thermal conductivity of aluminum alloys and their smooth surface, their reflectivity to lasers is relatively high, resulting in low absorption of laser energy. Moreover, because the melting and boiling points of aluminum alloys are relatively low, they are prone to volatilization during processing with high - energy heat sources. Therefore, additive manufacturing technologies using lasers and electron beams as heat sources have certain limitations in preparing high - strength aluminum alloys.

[0003] Arc wire additive manufacturing melts metal wire by an arc and, combined with the control of a robotic system, completes the additive manufacturing and forming of three - dimensional solid metal components by layer - by - layer stacking on a preset path. Since the arc energy distribution is not as concentrated as that of lasers and electron beams, and the upper limit of the energy density is relatively low, it is more suitable for the preparation of aluminum alloy components. However, because arc wire additive manufacturing is a surfacing process under a planned path, defects such as pores, inclusions, cracks, poor surface quality, and welding deformation will occur. The bonding between adjacent deposition layers of the formed aluminum alloy components is poor, thus affecting the mechanical properties, structural integrity, etc. of the aluminum alloy components, and seriously affecting the service performance of the components.

[0004] Regarding the problems existing in arc wire additive manufacturing, scholars at home and abroad have conducted a large number of exploratory studies on existing technologies. For example:

[0005] 1. Bharath Bhushan Ravichander et al. studied a new type of hybrid arc additive manufacturing and ultrasonic nanocrystal surface modification (UNSM) to modify the surface of 5356 aluminum alloy. This method reduced the surface roughness and reduced the welding deformation.

[0006] 2. Jun Xiao et al. explored the microstructure and mechanical properties of wire processed by laser shock peening and arc - additive - manufactured 2319 aluminum alloy. Using laser shock peening as a post - treatment for arc wire additive - manufactured 2319 aluminum alloy eliminated near - surface air voids and improved the surface macro - morphology;

[0007] 3. A method for reducing pores in aluminum alloy arc wire additive manufacturing is proposed in a Chinese patent with the publication number CN110834133A. This method reduces the pore defects in aluminum alloy arc wire additive manufacturing by regulating the ratio of the total auxiliary current I p to the total current I, thereby reducing the energy input. However, the equipment of this manufacturing method is complex and the safety factor is relatively low.

[0008] The above method has a certain effect on improving the surface morphology of aluminum alloy manufactured by arc wire additive manufacturing, but it cannot substantially change the bonding between adjacent deposited layers of the component, nor can it completely change the as-cast nature and organizational performance defects of arc wire additive manufacturing parts, such as poor mechanical properties like fatigue. Summary of the Invention

[0009] The purpose of the present invention is to provide a method for manufacturing metal components by arc wire additive manufacturing combined with non-pin friction stir for the problem of poor bonding between adjacent deposited layers of existing arc wire additive manufactured metal components. By combining the arc wire additive manufacturing + non-pin stirring process, the bonding between adjacent deposited layers is improved, thereby improving the mechanical properties and structural integrity of the component.

[0010] According to the purpose of the present invention, a method for manufacturing metal components by arc wire additive manufacturing combined with non-pin friction stir is provided, including the following steps:

[0011] Adopt the arc wire additive manufacturing process, and deposit layer by layer upward from the first layer on the substrate according to a preset printing program until the last layer is deposited to obtain the required metal component;

[0012] Among them, during the deposition process from the first layer to the last layer, each deposited layer is treated by non-pin friction stir to improve the surface finish of the current deposited layer, eliminate the oxide layer on the surface of the deposited layer, deepen the degree of mutual fusion between the next deposited layer and the current deposited layer, and at the same time redistribute the residual stress of the current deposited layer and eliminate segregation through non-pin friction stir, thereby improving the interlayer bonding between adjacent deposited layers.

[0013] As an optional implementation manner, the side surface of the metal component is treated by non-pin friction stir to improve the surface finish of the metal component.

[0014] As an optional implementation manner, the porosity of the metal component is less than 1%.

[0015] As an optional implementation manner, the surface roughness of the metal component is 3μm - 10μm.

[0016] As an optional implementation manner, when treated by non-pin friction stir, the pressing depth of the stirring head is 0.2mm - 0.4mm.

[0017] As an alternative embodiment, when the needleless friction stir treatment is adopted, the specific process parameters include: the shoulder diameter of the adopted stirring head is 12 mm to 18 mm, and the shoulder rotation speed is 800 rpm to 1000 rpm.

[0018] As an alternative embodiment, the thickness of each deposition layer is 1 mm to 5 mm.

[0019] As an alternative embodiment, the arc wire feeding additive manufacturing process is configured to determine the wire feeding speed and welding parameters according to the metal component parameters, and set the printing program accordingly to perform the printing and forming of the metal component.

[0020] As an alternative embodiment, the metal type of the metal component includes aluminum alloy.

[0021] As an alternative embodiment, post-treatment is performed on the metal component to improve the mechanical properties of the metal component and reduce surface defects, and the post-treatment process is configured to be determined according to the metal type of the metal component.

[0022] In the method for preparing a metal component by arc wire feeding additive manufacturing combined with needleless friction stir according to the present invention above, the arc wire feeding additive manufacturing technology and the needleless friction stir technology are combined. The metal wire is melted and deposited to obtain a deposition layer, and then the deposition layer is treated by needleless friction stir. Through the mechanical processing of needleless friction stir, the surface of the deposition layer is macroscopically flat. At the same time, needleless friction stir will cause plastic deformation of the metal deposition layer and can increase the temperature of the deposition layer surface, thereby triggering dynamic recrystallization, transforming the coarse columnar crystals or dendrites in the deposition layer into equiaxed crystals, improving the surface uniformity, reducing the unevenness caused by grain boundary misalignment, etc., so that the surface of the deposition layer is refined. At the same time, the oxide layer on the deposition layer surface is eliminated by needleless friction stir, so that the metals between layers can be fused with each other, eliminating the interface and enabling deeper metallurgical bonding between layers, reducing defects such as pores and lack of fusion;

[0023] On the other hand, the residual stress is redistributed through the local heat input and plastic deformation of needleless friction stir, avoiding peeling or cracking caused by stress differences between layers, and breaking up the coarse precipitates in the deposition layer structure by needleless friction stir and making them evenly distributed, avoiding the weakening of bonding caused by segregation;

[0024] In this way, the obtained component has high interlayer bonding and high compactness between adjacent deposition layers, a smooth surface, and excellent mechanical properties. Description of the Drawings

[0025] Figure 1 is a schematic diagram of an arc wire feeding additive manufacturing combined with needleless friction stir system in an example of the present invention.

[0026] Figure 2 This is the process flow chart of the method for preparing metal components by arc wire additive manufacturing combined with non - needle friction stir welding in the present invention.

[0027] Figure 3 This is the processing schematic diagram of the method for preparing metal components by arc wire additive manufacturing combined with non - needle friction stir welding in the present invention.

[0028] Figure 4 This is the schematic diagram before and after non - needle friction stir treatment in the example of the present invention.

[0029] Figure 5 This is the schematic diagram of the microstructure of the metal component in the example of the present invention. Detailed implementation manners

[0030] To better understand the technical content of the present invention, specific embodiments are given below in conjunction with the accompanying drawings for illustration.

[0031] In the present disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which many illustrative embodiments are shown. The embodiments of the present disclosure are not necessarily intended to cover all aspects of the present invention. It should be understood that the various concepts and embodiments introduced above, as well as those concepts and embodiments described in more detail below, can be implemented in any of many ways.

[0032] When using arc wire additive manufacturing technology to prepare metal components (for example, aluminum alloy components), there will be defects such as pores and cracks on the surface of the just - deposited deposition layer, the surface is uneven, and there are also tissue defects. If the next layer of material is directly deposited, the bonding between layers will be poor, and there will be many problems, which cannot meet the use requirements.

[0033] Therefore, the present invention aims to combine the arc wire additive manufacturing + non - needle friction stir welding process. By using non - needle friction stir treatment, the surface finish of the current deposition layer is improved, the oxide layer on the surface of the deposition layer is removed, the degree of mutual fusion between the next deposition layer and the current deposition layer is deepened, and at the same time, the residual stress of the current deposition layer is redistributed and segregation is eliminated through non - needle friction stir, thereby improving the inter - layer bonding between adjacent deposition layers. Thus, a metal component with a flat surface, good bonding between layers, and beautiful appearance can be efficiently produced, avoiding the problems of many surface defects and poor bonding between layers in the final material.

[0034] Arc Wire Additive Manufacturing Composite Non - needle Friction Stir System

[0035] Combined with Figure 1 As shown, the exemplary arc wire additive manufacturing combined with non - needle friction stir system of the present invention includes: a processing table 1, an arc wire additive manufacturing system 2, and a non - needle friction stir processing system 3.

[0036] The processing table 1 serving as a printing operation platform is horizontally installed on the bottom surface. A connecting part is provided on the worktable and is fitted with the substrate 11 to fix the substrate 11 on the worktable 1.

[0037] The arc wire - feeding additive manufacturing system 2 and the needle - less friction stir processing system 3 are arranged above the substrate 11, and the arc wire - feeding additive manufacturing system 2 and the needle - less friction stir processing system 3 are at the same horizontal height.

[0038] The arc wire - feeding additive manufacturing system 2 includes a wire - feeding mechanism 21, a welding torch 22, and a gas protection device 23.

[0039] The wire - feeding mechanism 21 is used to send the metal welding wire to the front end of the welding torch during the printing process. A commercially available automatic wire - feeding device can be used to complete the transportation of the metal wire according to a preset program. In the actual printing process, multiple groups of wire - feeding mechanisms can be set as needed to feed wire simultaneously.

[0040] An arc is generated at the tip of the welding torch 22 through the provided welding box 24 to melt the metal wire into a molten state, and printing work is carried out on the substrate according to the path planned by the slicing software.

[0041] The gas protection device 23 continuously transports the required protective gas according to the demand during the printing process to prevent the workpiece from oxidation and avoid defects in the workpiece.

[0042] The needle - less friction stir processing system 3 includes a needle - less stirring head 31 and a control system 32. The needle - less stirring head 31 is used to perform needle - less friction stir treatment on the surface of the deposition layer, and the control system 32 is used to control the rotation speed, movement rate, and travel path of the needle - less stirring head 31 so that the needle - less stirring head 31 processes the surface of the deposition layer 4 according to the planned path.

[0043] Method for Preparing Metal Components by Arc Wire Additive Manufacturing Composite Non - needle Friction Stir

[0044] Combined Figure 2 、 3 As shown, on the basis of the system shown in Figure 1 In an exemplary use process, taking the preparation of an aluminum alloy component as an example, the method for preparing a metal component by arc wire - feeding additive manufacturing combined with needle - less friction stir includes the following steps:

[0045] Step 1: Before preparing the aluminum alloy component, first clean the substrate 11, for example, wash the oil stain on the surface with acetone, and then fix the substrate 11 on the worktable 1.

[0046] Step 2: Feed the aluminum alloy wire through the wire feeding mechanism 21 to the tip of the welding torch 22. The welding box 24 forms an electric arc at the tip of the welding torch 22, melts the wire into metal droplets in an argon atmosphere, and deposits the melted aluminum alloy wire onto the substrate according to the path planned by the slicing software, printing a deposited layer 4 with a thickness of 1 mm to 5 mm.

[0047] It should be understood that if the deposited layer is too thick, the local heat of the aluminum alloy layer cannot be dissipated in time, resulting in thermal cracks. When multiple layers are deposited, the heat accumulation will increase, which may cause grain coarsening, thereby reducing the mechanical properties of the component. At the same time, the shrinkage stress after cooling of the too-thick deposited layer is greater, which will weaken the metallurgical bonding with the next deposited layer; if the deposited layer is too thin, the production efficiency will be reduced, the molten pool size will be too small, the interlayer heat affected zone will be insufficient, the bonding strength will decrease, and at the same time, the cooling rate of the deposited layer will be too fast, thereby introducing local high residual stress and increasing the risk of part warping.

[0048] Step 3: Use the control system 32 to control the non-pin friction stir head 31, and make the non-pin friction stir head 31 perform non-pin friction stir treatment on the surface of the deposited layer 4 obtained in Step 2 according to the planned path.

[0049] Step 4: Repeat Steps 2 and 3 in a loop until the aluminum alloy component 5 is printed.

[0050] Step 5: Use the non-pin friction stir head 31 to perform surface leveling treatment on the side of the aluminum alloy component 5.

[0051] Step 6: Select a post-treatment process according to the type of aluminum alloy, and perform post-treatment on the aluminum alloy component completed in Step 5, such as heat treatment or aging treatment, to further improve the mechanical properties of the component and reduce the defects on the surface of the component.

[0052] Combined Figure 4 、 5 As shown, the method for preparing metal components by arc wire feeding additive manufacturing combined with non-pin friction stir proposed by the present invention strengthens the interlayer bonding layer by layer in a coordinated manner. Immediately after each layer is deposited, non-pin friction stir treatment is carried out. Through the dual mechanisms of mechanical action (plastic deformation) and thermal action (local temperature rise), the surface state of the deposited layer is improved in real time. On the one hand, immediately after each layer is deposited, non-pin friction stir treatment is carried out. The mechanical friction and plastic flow of non-pin friction stir (without a stirring pin head) can remove the oxide film on the surface of the deposited layer, prevent the oxide layer from becoming a physical barrier to interlayer bonding, and promote direct contact between the upper and lower layers of metal and form metallurgical bonding; on the other hand, it triggers dynamic recrystallization, converts the coarse columnar grains / dendrites into uniform equiaxed grains, reduces the surface unevenness caused by grain boundary misalignment, makes the interlayer contact closer and the fusion more sufficient. Thus, through the "deposition-treatment-redeposition" cycle mode, the problem of weak interlayer bonding caused by surface roughness, oxidation or non-uniform structure in traditional additive manufacturing is avoided from the process source.

[0053] Combined with the composite process treatment of the present invention, the local plastic deformation and heat input of the non-pin friction stir treatment can redistribute the residual stress in the deposited layer, avoid peeling or cracking caused by stress concentration between layers, and improve the overall structural stability of the component. Through mechanical crushing and homogenization, coarse precipitates are broken up and segregation (such as alloy element aggregation) is inhibited, reducing the weakening of the bonding interface caused by composition inhomogeneity, achieving the continuity of composition and microstructure between layers, and reducing metallurgical defects at the interface.

[0054] For the treated metal component, the surface roughness also decreases from the initial 20 μm - 100 μm to the range of 3 μm - 10 μm, which not only ensures the surface finish but also provides a high-quality substrate for the subsequent deposited layer, forming a virtuous cycle. And the porosity is less than 1%, and can even reach less than 0.5%, especially in the range of 0.2% - 0.3%, which is significantly lower than that of traditional arc wire additive manufacturing (usually with defects such as pores and lack of fusion). It can be seen from this that both the interlayer bonding and the surface finish of the treated metal component are improved. By eliminating the oxide layer and enhancing the metallurgical bonding, the interlayer shear strength and tensile strength are directly increased, avoiding the problem of fracture along the interlayer interface in traditional additive manufacturing, and enabling adjacent layers to form a "quasi-integral" structure rather than a simple stack. Moreover, the refinement of the microstructure and the elimination of segregation reduce the anisotropy of the material, improve the plasticity and fracture toughness, and are especially suitable for the rapid manufacturing of high-load-bearing components with high requirements for comprehensive mechanical properties (such as aerospace aluminum alloy components).

[0055] As an optional example, when using non-pin friction stir for treatment, the shoulder diameter of the stirring head used is 12 mm - 18 mm, and the working end face of the shoulder can have patterns, such as spiral patterns.

[0056] As an optional example, when using non-pin friction stir for treatment, the specific process parameters include: the shoulder rotation speed is 800 rpm - 1000 rpm, and the pressing depth is 0.2 mm - 0.4 mm.

[0057] As an optional example, the arc wire additive manufacturing process is set to determine the wire feeding speed and welding parameters according to the metal component parameters, and set the printing program accordingly to perform the printing and forming of the metal component.

[0058] As an optional example, the process parameters of arc additive manufacturing include:

[0059] The wire feeding speed of the wire feeder is 1 m / min - 8.5 m / min, the angle between the wire feeder and the welding torch is 40° - 60°, the distance between the welding torch and the substrate is 10 mm - 20 mm, the welding current is 150 A - 250 A, the welding voltage is 18 V - 28 V, and the welding speed is 0.3 m / min - 1.5 m / min.

[0060] As an optional example, the process of arc additive manufacturing is carried out in an atmosphere of protective gas, and the protective gas includes argon with a constant flow rate of 20 L / min to 25 L / min.

[0061] For better understanding, the present invention will be further described below in conjunction with several specific examples, but the preparation process is not limited thereto, and the content of the present invention is not limited thereto.

[0062] Unless otherwise specified, the materials in the examples are prepared according to existing methods or directly purchased from the market.

[0063] The printed component is a cuboid with a length × width × height = 150 mm × 80 mm × 10 mm.

[0064] Example 1

[0065] (1) The wire used is an Al-6.2Zn-2.2Mg alloy, the diameter of the wire is 1.2 mm, and the wire is fed by a WPC-600 wire feeder.

[0066] (2) The substrate is an H111-5083 aluminum alloy with a size of 300 mm × 100 mm × 3 mm. Before use, the substrate is cleaned with acetone and a steel brush.

[0067] (3) Argon with a purity of 99.99% is used as the protective gas, and the constant flow rate is 20 L / min; the distance between the welding torch and the substrate is 15 mm, and the welding current, voltage, and welding speed are 150 A, 20 V, and 0.5 m / min, respectively; the angle between the wire feeder and the welding torch is set to 40°; the wire feeding speed is 2.5 m / min, and the layer thickness of each layer is set to 2 mm.

[0068] After printing the first layer of aluminum alloy using the above parameters and after printing, the surface of the alloy is finish-treated using an H13 needleless cylindrical stirring head with a shoulder diameter of 15 mm, the rotational speed is 950 rpm, and the pressing depth is 0.2 mm.

[0069] (4) Repeat the printing and needleless friction stir process of step (3) until a complete Al-6.2Zn-2.2Mg alloy component is printed.

[0070] (5) The side surface of the alloy component is finish-treated using the needleless stirring technology, the rotational speed is 800 rpm, and the pressing depth is 0.3 mm.

[0071] (6) Heat the component from 30 °C to 470 °C at a heating rate of 30 °C / min, hold for 1 h, then rapidly cool the component in water at 20 °C. Reheat the component from 30 °C to 120 °C at a heating rate of 15 °C / min, hold for 24 h, and air cool to room temperature. Conduct the entire heat treatment process under an argon atmosphere.

[0072] Example 2

[0073] (1) The wire used is an Al-Cu-Mg-Ag alloy wire with a diameter of 1.2 mm, and it is fed by a 4000R NC CMT wire feeder.

[0074] (2) Use an Al-2024 alloy as the substrate with dimensions of 300 mm × 100 mm × 3 mm. Clean the substrate with acetone and a steel brush before use.

[0075] (3) Use argon with a purity of 99.99% as the shielding gas with a constant flow rate of 20 L / min; the distance between the welding torch and the substrate is 15 mm, and the welding current, voltage, and welding speed are 200 A, 20 V, and 0.5 m / min respectively. Set the angle between the wire feeder and the welding torch to 40°, the wire feeding speed of the wire feeder to 2.8 m / min, and the layer thickness of each layer to 3 mm.

[0076] Print the first layer of aluminum alloy with the above parameters. After printing, use an H13 needleless cylindrical stirring head with a shoulder diameter of 12 mm to finish the surface of the alloy. The rotation speed is 950 rpm, and the pressing depth is 0.3 mm.

[0077] (4) Repeat the printing and needleless friction stir process in step (3) until a complete Al-Cu-Mg-Ag alloy component is printed.

[0078] (5) Use the needleless stirring technique to finish the side surface of the alloy component. The rotation speed is 1000 rpm, and the pressing depth is 0.3 mm.

[0079] (6) Place the component in a muffle furnace and heat it at a temperature of 520 °C for 10 h. Then, conduct water cooling treatment on the component. After that, conduct tempering treatment on the component, hold it at a temperature of 165 °C for 2 h, and air cool.

[0080] Comparative Example 1

[0081] (1) The wire used is an Al-6.2Zn-2.2Mg alloy, the diameter of the wire is 1.2 mm, and it is fed by a WPC-600 wire feeder.

[0082] (2) Use the H111-5083 aluminum alloy as the substrate, with dimensions of 300 mm × 100 mm × 3 mm. Before use, clean the substrate with acetone and a steel brush.

[0083] (3) Use argon with a purity of 99.99% as the shielding gas, with a constant flow rate of 20 L / min; the distance between the welding torch and the substrate is 15 mm, and the welding current, voltage, and welding speed are 150 A, 20 V, and 0.5 m / min respectively; the angle between the wire feeder and the welding torch is set at 40°; the wire feeding speed is 2.5 m / min, and the layer thickness for each layer is set at 2 mm.

[0084] (4) Layer by layer printing is carried out according to the three-dimensional model path in the slicing software until the entire Al-6.2Zn-2.2Mg alloy component is prepared.

[0085] (5) Heat the component from 30 °C to 470 °C at a heating rate of 30 °C / min, hold for 1 h, then quickly cool the component in water at 20 °C. Then, heat the component from 30 °C to 120 °C again at a heating rate of 15 °C / min, hold for 24 h, and air-cool to room temperature. The entire heat treatment process is carried out under an argon atmosphere.

[0086] Comparative Example 2

[0087] (1) The wire used is an Al-Cu-Mg-Ag alloy wire with a diameter of 1.2 mm, and the wire is fed by a 4000R NC CMT wire feeder.

[0088] (2) Use the Al-2024 alloy as the substrate, with dimensions of 300 mm × 100 mm × 3 mm. Before use, clean the substrate with acetone and a steel brush.

[0089] (3) Use argon with a purity of 99.99% as the shielding gas, with a constant flow rate of 20 L / min; the distance between the welding torch and the substrate is 15 mm, and the welding current, voltage, and welding speed are 200 A, 20 V, and 0.5 m / min respectively. The angle between the wire feeder and the welding torch is set at 40°, the wire feeding speed of the wire feeder is 2.8 m / min, and the layer thickness for each layer is set at 3 mm.

[0090] (4) Layer by layer printing is carried out according to the three-dimensional model path in the slicing software until the entire Al-6.2Zn-2.2Mg alloy component is prepared.

[0091] (5) Place the component in a muffle furnace, heat it at a temperature of 520 °C for 10 h, then carry out water cooling treatment on the component. After that, carry out tempering treatment on the component, hold it at a temperature of 165 °C for 2 h, and air-cool.

[0092] Performance Test

[0093] The performance tests were carried out on the samples of Examples 1-2 and Comparative Examples 1-2, and the results are shown in Table 1.

[0094] Table 1

[0095] Tensile Strength / MPa Elongation / % Microhardness / HV Porosity / % Example 1 490 10 170 0.3 Example 2 510 11.2 165 0.2 Comparative Example 1 402 5.51 150 1.2 Comparative Example 2 450 6 140 1.3

[0096] As can be seen from Table 1, for the aluminum alloy components prepared by the method of the present invention, the tensile strength, elongation and microhardness have all been improved to a certain extent compared with the components without needleless stirring treatment. This shows that the present invention improves the bonding between adjacent deposition layers by combining the arc wire additive manufacturing + needleless stirring process, thereby improving the mechanical properties of the components. Moreover, the porosity of the components in Examples 1 and 2 has decreased significantly compared with that of the components in Comparative Examples 1 and 2, and the porosity is less than 1%, further indicating the improvement of the bonding performance of the components; the surface of the printed components is smooth and flat, and the surface roughness has decreased from about 50 μm to about 8 μm, indicating that needleless stirring can reduce the pore defects in the aluminum alloy components, improve the compactness of the components, and the surface and structural integrity of the obtained components, thereby improving the service performance of the components.

[0097] Although the present invention has been disclosed above with preferred embodiments, it is not intended to limit the present invention. Those with ordinary knowledge in the technical field to which the present invention pertains can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be subject to what is defined by the claims.

Claims

1. A method for preparing a metal component by arc fuse additive manufacturing composite needle-free friction stir, characterized in that: The following steps are involved: Using the arc fuse additive manufacturing process, the material is deposited layer by layer on the substrate in an upward growth manner starting from the first layer according to the preset printing program until the last layer is deposited to obtain the required metal component; Among them, during the deposition process from the first layer to the last layer, each deposited layer is treated with needle-free stirring friction to improve the surface finish of the current deposited layer, eliminate the oxide layer on the surface of the deposited layer, deepen the degree of mutual fusion between the next deposited layer and the current deposited layer, and at the same time, redistribute the residual stress of the current deposited layer and eliminate segregation through needle-free stirring friction, thereby improving the interlayer bonding between adjacent deposited layers.

2. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: The side surface of the metal component is processed by needle-free friction stirring to improve the surface finish of the metal component.

3. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: The porosity of the metal component is less than 1%.

4. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: The surface roughness of the metal component is between 3 μm and 10 μm.

5. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: When the needle-free stirring friction is used for treatment, the pressing depth of the stirring head is 0.2 mm to 0.4 mm.

6. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: When the needle-free friction stir treatment is used, the specific process parameters include: the shoulder diameter of the stirring head used is 12 mm to 18 mm, and the shoulder rotation speed is 800 rpm to 1000 rpm.

7. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: The thickness of each deposition layer is 1 mm to 5 mm.

8. The method for preparing metal components by arc fuse additive manufacturing composite needle-free friction stir according to claim 1, characterized in that: The arc fuse additive manufacturing process is configured to determine the wire feeding speed and welding parameters according to the parameters of the metal component, and to set the printing program accordingly to print and form the metal component.

9. The method for preparing a metal component by arc fuse additive manufacturing composite needle-free friction stir according to any one of claims 1 to 8, characterized in that: The metal type of the metal member includes aluminum alloy.

10. The method for preparing a metal component by arc fuse additive manufacturing composite needle-free friction stir according to any one of claims 1 to 8, characterized in that: The metal component is post-processed to improve the mechanical properties of the metal component and reduce surface defects, and the post-processing process is set to be determined according to the metal type of the metal component.

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