Application of electric arc wire feeding technology in the preparation of aero-engine turbine disk materials

Abstract

This invention discloses the application of arc-fed wire feeding technology in the preparation of aero-engine turbine disk materials, belonging to the field of aero-engine turbine disk manufacturing technology. It involves using GH4169 high-temperature alloy as the base wire, electroplating TiC nanoparticles and Al2O3 nanoparticles to form a coating layer, producing a composite wire. An ultrasonic-assisted arc-fed wire feeding additive manufacturing process is then performed, with the ultrasonic action area covering the molten pool along the liquid / solid two-phase region. When the deposition layer temperature drops to a set temperature, alternating vertical and horizontal forging is performed in a multi-directional micro-forging process. Finally, heat treatment is conducted to obtain the aero-engine turbine disk material. This invention successfully solves the technical problems of coarse microstructure, numerous defects, and unstable performance in traditional additive manufacturing of aero-engine turbine disk materials through the synergistic effect of ultrasonic-assisted arc-fed wire feeding additive manufacturing, nanoparticle composite reinforcement, and synchronous multi-directional micro-forging.

Description

Technical Field

[0001] This invention relates to the field of aero-engine turbine disk manufacturing technology, specifically to the application of arc wire feeding technology in the preparation of aero-engine turbine disk materials. Background Technology

[0002] The forging and manufacturing of high-temperature alloy turbine disks requires first smelting high-quality high-temperature alloy ingots, followed by billet preparation. Through forging ratio control, upsetting, drawing, and other processes, the internal structure of the ingot is improved, large columnar crystals and casting defects are broken, and the material density and uniformity are increased. The billet is then heated to a suitable temperature and die-forged using a die, allowing the metal to plastically flow under pressure and fill the die cavity to form the approximate shape of the turbine disk. Subsequent multiple precision forging passes are then used to gradually achieve the design dimensions and accuracy requirements. Finally, heat treatment is performed to optimize the alloy microstructure and improve properties such as strength, hardness, and fatigue resistance.

[0003] The manufacturing of high-temperature alloy turbine disks using powder metallurgy begins with powder preparation. The high-temperature alloy melt is broken into fine powder particles using an atomization method. The powder is then screened and graded, placed in a special enclosure, vacuum-sealed, and subjected to hot isostatic pressing. Under high temperature and pressure, the powder is densified to form a blank resembling the shape of a turbine disk. Hot extrusion or forging further improves the microstructure and properties, refines the grains, and increases the material's density and uniformity. Finally, heat treatment eliminates residual stress and optimizes the microstructure, ensuring the turbine disk meets performance requirements.

[0004] However, the forging process is complicated, involving multiple heating, forging and heat treatment processes, resulting in a long processing cycle. It usually takes several weeks or even months to manufacture a turbine disk. Moreover, during the forging process, a large amount of metal is removed due to machining allowances, flash, etc., resulting in low material utilization and serious waste. The long cycle and low utilization rate significantly increase manufacturing costs. The high cost limits the research and development and production scale of aero engines, and hinders the application of new technologies and performance improvement.

[0005] Powder metallurgy has high requirements for equipment and environment. The equipment investment in powder preparation, hot isostatic pressing, and other stages is substantial, and strict process control increases production costs. Furthermore, the powder is susceptible to contamination during the process, affecting product quality. To ensure quality, additional testing and control measures are needed, further increasing costs. Although material utilization is improved compared to forging, the complexity of equipment and processes results in high overall costs. Additionally, the long production cycle hinders the rapid response to the R&D and production needs of aero-engines, impeding the rapid iteration and development of aero-engine technology.

[0006] When using existing traditional additive manufacturing technology to prepare high-temperature alloy turbine disks, the alloy material only undergoes free melting, stacking, cooling, and solidification processes, lacking dynamic deformation. As a result, the alloy crystals inevitably recrystallize and grow, leading to a decrease in mechanical properties. At the same time, traditional additive processes are prone to generating residual stress during layer-by-layer stacking, which can easily cause deformation and crack initiation during service, affecting the fatigue life of the turbine disk.

[0007] The existing technology CN101985167B discloses the casting process of the turbine assembly. The turbine disk and turbine blades are firmly connected after molding, with good stability and strong connection. The process steps are simple and direct molding, and there is basically no scrap in the casting process. However, it does not solve the technical problems of coarse structure, many defects and unstable performance of traditional additive manufacturing of aero-engine turbine disk materials. Summary of the Invention

[0008] This invention discloses the application of electric arc wire feeding technology in the preparation of aero-engine turbine disk materials. Through the synergistic effect of ultrasonic-assisted electric arc wire feeding additive manufacturing, nanoparticle composite reinforcement, and synchronous multi-directional micro-forging, the technical problems of coarse microstructure, numerous defects, and unstable performance of traditional additive manufacturing aero-engine turbine disk materials are successfully solved.

[0009] The application of the arc wire feeding process of the present invention in the preparation of aero-engine turbine disk materials involves selecting GH4169 high-temperature alloy as the base wire, using electroplating to form a coating layer on the precursor to obtain a composite wire, performing an ultrasonic-assisted arc wire feeding additive manufacturing process, with the ultrasonic action area covering the liquid / solid two-phase region along the rear edge of the molten pool, and performing multi-directional micro-forging with alternating vertical and horizontal forging when the temperature of the deposited layer drops to a set temperature, and finally performing heat treatment to obtain the aero-engine turbine disk material.

[0010] As a further improvement to the present invention, the following steps are included:

[0011] S1. Preparation of composite wire: GH4169 high-temperature alloy was selected as the base wire, and the precursor was formed on the surface of the wire by electroplating to obtain the composite wire.

[0012] The precursor includes TiC nanoparticles and Al2O3 nanoparticles;

[0013] The TiC nanoparticles are composed of titanium powder and graphite powder, and the coating matrix is ​​a nickel-based binder.

[0014] S2. Ultrasonic-assisted arc wire feeding additive manufacturing process: The composite wire is subjected to arc wire feeding additive manufacturing process. After the arc is ignited, the ultrasonic wave is activated. The ultrasonic action area covers the molten pool and extends along the liquid / solid two-phase region.

[0015] S3. Synchronous multi-directional micro-forging: Multi-directional forging begins when the temperature of the deposited layer drops to the set temperature;

[0016] The multi-directional forging system includes vertical forging and horizontal forging;

[0017] S4. Heat treatment process: solution treatment, aging treatment and stress relief are carried out to obtain the turbine disk material for aero-engines.

[0018] As a further improvement of the present invention, the precursor content accounts for 0.5% to 2.0% of the total mass of the composite filament.

[0019] As a further improvement of the present invention, in the arc wire feeding additive manufacturing process, the interlayer temperature is controlled at 150-250℃ and the deposition rate is 3-6 mm / s.

[0020] As a further improvement of the present invention, the current of the electric arc wire feeding additive manufacturing process is 280-350A, the voltage is 24-28V, and the wire feeding speed is 4-8m / min.

[0021] As a further improvement of the present invention, the ultrasonic frequency is 40-60kHz and the power density is 1.2~1.8W / cm². 2 .

[0022] As a further improvement of the present invention, the forging frequency of the multi-directional forging is 10 to 15 times / minute, the duration of each forging is 0.1 to 0.3 seconds, and the forging direction alternates between 90° vertical forging and 0° horizontal forging in a ratio of 2:1.

[0023] As a further improvement of the present invention, the 90° vertical forging pressure of the multi-directional forging system is 15-25 MPa, and the 0° horizontal forging pressure is 10-20 MPa.

[0024] As a further improvement of the present invention, the forging head material used in the multi-directional forging system is H13 hot work die steel with a hardness of HRC48-52. The forging head is cylindrical with a diameter of 20-30mm. The forging force loading rate is 50-100MPa / s, and the unloading rate is 20-50MPa / s.

[0025] As a further improvement to the present invention, the specific steps include:

[0026] S1. Preparation of composite wire: GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the base wire. The precursor was electroplated to form a coating layer with a thickness of 5-15 μm on the surface of the wire to obtain the composite wire. The precursor content accounted for 0.5% to 2.0% of the total mass of the composite wire.

[0027] The precursor is composed of TiC nanoparticles with a particle size of 20-50 nm and Al2O3 nanoparticles with a particle size of 30-80 nm.

[0028] The TiC nanoparticles are composed of titanium powder with a particle size of less than 5 μm and graphite powder with a particle size of less than 2 μm in a molar ratio of 1:1, and the coating matrix is ​​a nickel-based binder with a thickness of 2-5 μm.

[0029] S2. Ultrasonic-assisted arc wire feeding additive manufacturing process: The composite wire is subjected to arc wire feeding additive manufacturing process. After the arc is ignited, the ultrasonic wave is started. The ultrasonic action area covers the liquid / solid two-phase region after the molten pool. The interlayer temperature is controlled at 150-250℃ and the deposition rate is 3-6mm / s.

[0030] The current of the electric arc wire feeding additive manufacturing process is 280-350A, the voltage is 24-28V, and the wire feeding speed is 4-8m / min.

[0031] The ultrasonic frequency is 40-60kHz, and the power density is 1.2~1.8W / cm². 2 ;

[0032] S3. Synchronous multi-directional micro-forging: When the temperature of the deposited layer drops to 800-900℃, multi-directional forging begins. The forging frequency is 10-15 times / minute, and the duration of each forging is 0.1-0.3 seconds. The forging direction alternates between 90° forging and 0° forging in a ratio of 2:1.

[0033] The vertical forging pressure of the multi-directional forging system is 15-25 MPa, and the horizontal forging pressure is 10-20 MPa.

[0034] The forging head material used in the multi-directional forging system is H13 hot work die steel with a hardness of HRC48-52. The forging head is cylindrical with a diameter of 20-30mm. The forging force loading rate is 50-100MPa / s, and the unloading rate is 20-50MPa / s.

[0035] S4. Heat treatment process: Solution treatment is performed, and the temperature is held at 1065℃ for 1 hour, followed by air cooling. Then, aging treatment is performed, and the temperature is held at 720℃ for 8 hours, followed by furnace cooling to 620℃ and holding for 8 hours, followed by air cooling. Then, stress relief is performed, and the temperature is held at 650℃ for 3 hours, followed by air cooling, to obtain the turbine disk material for aero-engines.

[0036] The present invention has the following beneficial effects:

[0037] (1) The present invention significantly improves the strength of aero-engine turbine disks through the synergistic effect of nanoparticle composite reinforcement, ultrasonic-assisted fine grain strengthening and multi-directional forging densification.

[0038] (2) The present invention promotes the homogenization of the molten pool through ultrasonic flow effect, and eliminates interlayer defects and pores through multi-directional forging, effectively solving the problem of insufficient fatigue performance of traditional additive manufacturing materials.

[0039] (3) The present invention refines the grain size through the cavitation effect and acoustic flow effect generated by ultrasonic frequency, and simultaneously improves the material density to more than 99.5% through multi-directional micro forging, thus eliminating the technical problems of coarse structure and many defects in traditional additive manufacturing.

[0040] (4) The present invention provides dispersion reinforcement through TiC and Al2O3 nanoparticles, achieves fine grain reinforcement with ultrasonic assistance, and ensures the densification of the microstructure through multi-directional forging. The organic combination of the three reinforcement mechanisms produces a synergistic effect and improves the mechanical properties of the material.

[0041] (5) By precisely controlling the interlayer temperature of 150-250℃, the forging frequency of 10-15 times / minute, and the vertical forging pressure of 15-25MPa, this invention reduces the standard deviation of mechanical properties in the manufacturing process and provides reliable technical support for industrial production. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the simultaneous multi-directional micro-forging process using arc wire feeding additive manufacturing in Embodiment 1 of this application;

[0043] Figure 2 This is a schematic diagram of the wire feeding device for the arc wire feeding additive manufacturing process in Embodiment 1 of this application;

[0044] Figure 3 This is a schematic diagram of the forging head used in the multi-directional forging system in Embodiment 1 of this application. Detailed Implementation

[0045] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0046] Example 1

[0047] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 25 nm and Al2O3 nanoparticles with a particle size of 35 nm were mixed at a mass ratio of 1:1. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 3 μm and graphite powder with a particle size of 1.5 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 3 μm was used for coating. An 8 μm thick coating layer was formed on the surface of the matrix wire by electroplating. The precursor content accounted for 1.0% of the total mass of the composite wire, thus obtaining the composite wire.

[0048] Arc-feed additive manufacturing process for composite filaments (see schematic diagram of the wire feeding device used in arc-feed additive manufacturing process). Figure 2 As shown in the figure, the current is set to 300A, the voltage to 25V, the wire feed speed to 5m / min, the interlayer temperature to be controlled at 180℃, the deposition rate to be 4mm / s, and the ultrasonic wave is started after the electric arc is ignited, with an ultrasonic frequency of 45kHz and a power density of 1.4W / cm³. 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0049] When the deposition layer temperature drops to 850℃, multi-directional forging begins (see schematic diagram of simultaneous multi-directional micro-forging in arc wire feeding additive manufacturing process). Figure 1 (As shown), the forging frequency is 12 times / minute, each forging lasts 0.2 seconds, and the forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 20MPa, and the horizontal forging pressure is 15MPa. A 25mm diameter H13 hot work die steel forging head is used (see schematic diagram of the forging head used in the multi-directional forging system). Figure 3 As shown), the hardness is HRC50, the forging force loading rate is 75MPa / s, and the unloading rate is 35MPa / s.

[0050] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0051] Example 2

[0052] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 30 nm and Al2O3 nanoparticles with a particle size of 40 nm were mixed at a mass ratio of 1.2:1. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 2.5 μm and graphite powder with a particle size of 1 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 4 μm was used for coating. An electroplating method was used to form a coating layer with a thickness of 12 μm on the surface of the matrix wire. The precursor content accounted for 1.5% of the total mass of the composite wire, thus obtaining the composite wire.

[0053] An electric arc feeding additive manufacturing process was performed on the composite filament. The settings were: current 320A, voltage 26V, wire feeding speed 6m / min, interlayer temperature 200℃, deposition rate 5mm / s. After arc ignition, ultrasonic waves were initiated at a frequency of 50kHz and a power density of 1.6W / cm². 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0054] Multi-directional forging begins when the deposition layer temperature drops to 880℃. The forging frequency is 13 times / minute, with each forging lasting 0.25 seconds. The forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 22MPa, and the horizontal forging pressure is 18MPa. A 28mm diameter H13 hot work die steel forging head with a hardness of HRC51 is used. The forging force loading rate is 85MPa / s, and the unloading rate is 40MPa / s.

[0055] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0056] Example 3

[0057] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 20 nm and Al2O3 nanoparticles with a particle size of 30 nm were mixed at a mass ratio of 0.8:1. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 4 μm and graphite powder with a particle size of 1.8 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 2 μm was used for coating. An electroplating method was used to form a coating layer with a thickness of 5 μm on the surface of the matrix wire. The precursor content accounted for 0.5% of the total mass of the composite wire, thus obtaining the composite wire.

[0058] An electric arc feeding additive manufacturing process was performed on the composite filament. The settings were: current 280A, voltage 24V, wire feeding speed 4m / min, interlayer temperature 150℃, deposition rate 3mm / s. After arc ignition, ultrasonic waves were initiated at a frequency of 40kHz and a power density of 1.2W / cm². 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0059] Multi-directional forging begins when the deposition temperature drops to 800℃. The forging frequency is 10 times / minute, with each forging lasting 0.1 seconds. The forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 15MPa, and the horizontal forging pressure is 10MPa. A 20mm diameter H13 hot work die steel forging head with a hardness of HRC48 is used. The forging force loading rate is 50MPa / s, and the unloading rate is 20MPa / s.

[0060] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0061] Example 4

[0062] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 45 nm and Al2O3 nanoparticles with a particle size of 70 nm were mixed at a mass ratio of 1.5:1. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 4.5 μm and graphite powder with a particle size of 1.2 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 4.5 μm was used for coating. An electroplating method was used to form a coating layer with a thickness of 14 μm on the surface of the matrix wire. The precursor content accounted for 1.8% of the total mass of the composite wire, thus obtaining the composite wire.

[0063] An electric arc feeding additive manufacturing process was performed on the composite filament. The settings were: current 340A, voltage 27V, wire feeding speed 7m / min, interlayer temperature controlled at 230℃, deposition rate 5.5mm / s. After arc ignition, ultrasonic waves were initiated at a frequency of 55kHz and a power density of 1.7W / cm². 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0064] Multi-directional forging begins when the deposition layer temperature drops to 870℃. The forging frequency is 14 times / minute, with each forging lasting 0.28 seconds. The forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 24MPa, and the horizontal forging pressure is 19MPa. A 27mm diameter H13 hot work die steel forging head with a hardness of HRC51 is used. The forging force loading rate is 90MPa / s, and the unloading rate is 45MPa / s.

[0065] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0066] Example 5

[0067] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 50 nm and Al2O3 nanoparticles with a particle size of 80 nm were mixed at a mass ratio of 1:1.2. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 5 μm and graphite powder with a particle size of 2 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 5 μm was used for coating. An electroplating method was used to form a coating layer with a thickness of 15 μm on the surface of the matrix wire. The precursor content accounted for 2.0% of the total mass of the composite wire, thus obtaining the composite wire.

[0068] An electric arc feeding additive manufacturing process was performed on the composite filament. The settings were: current 350A, voltage 28V, wire feeding speed 8m / min, interlayer temperature 250℃, deposition rate 6mm / s. After arc ignition, ultrasonic waves were initiated at a frequency of 60kHz and a power density of 1.8W / cm². 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0069] Multi-directional forging begins when the deposition layer temperature drops to 900℃. The forging frequency is 15 times / minute, with each forging lasting 0.3 seconds. The forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 25MPa, and the horizontal forging pressure is 20MPa. A 30mm diameter H13 hot work die steel forging head with a hardness of HRC52 is used. The forging force loading rate is 100MPa / s, and the unloading rate is 50MPa / s.

[0070] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0071] Comparative Example 1 differs from Example 1 in that no ultrasonic assistance is used in the arc wire feeding additive manufacturing process.

[0072] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 25 nm and Al2O3 nanoparticles with a particle size of 35 nm were mixed at a mass ratio of 1:1. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 3 μm and graphite powder with a particle size of 1.5 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 3 μm was used for coating. An 8 μm thick coating layer was formed on the surface of the matrix wire by electroplating. The precursor content accounted for 1.0% of the total mass of the composite wire, thus obtaining the composite wire.

[0073] The composite filament was processed using a traditional electric arc feeding additive manufacturing process, with the current set at 300A, voltage at 25V, and wire feeding speed at 5m / min. The interlayer temperature was controlled at 180℃, and the deposition rate at 4mm / s. The ultrasonic system was not activated during the entire additive manufacturing process.

[0074] Multi-directional forging begins when the deposition layer temperature drops to 850℃. The forging frequency is 12 times / minute, with each forging lasting 0.2 seconds. The forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 20MPa, and the horizontal forging pressure is 15MPa. A 25mm diameter H13 hot work die steel forging head with a hardness of HRC50 is used. The forging force loading rate is 75MPa / s, and the unloading rate is 35MPa / s.

[0075] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0076] Comparative Example 2 differs from Example 1 in that it does not involve simultaneous multi-directional forging.

[0077] GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the matrix wire. When preparing the precursor, TiC nanoparticles with a particle size of 25 nm and Al2O3 nanoparticles with a particle size of 35 nm were mixed at a mass ratio of 1:1. The TiC nanoparticles were prepared by mixing titanium powder with a particle size of 3 μm and graphite powder with a particle size of 1.5 μm at a molar ratio of 1:1. A nickel-based binder with a thickness of 3 μm was used for coating. An 8 μm thick coating layer was formed on the surface of the matrix wire by electroplating. The precursor content accounted for 1.0% of the total mass of the composite wire, thus obtaining the composite wire.

[0078] An electric arc feeding additive manufacturing process was performed on the composite filament. The settings were: current 300A, voltage 25V, wire feeding speed 5m / min, interlayer temperature 180℃, deposition rate 4mm / s. After arc ignition, ultrasonic waves were initiated at a frequency of 45kHz and a power density of 1.4W / cm². 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0079] After additive manufacturing, the material is directly heat-treated without any forging process. It undergoes solution treatment, holds at 1065℃ for 1 hour and air-cools, followed by aging treatment, holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air-cooling. Finally, it undergoes stress relief, holding at 650℃ for 3 hours and air-cooling to obtain the turbine disk material for aero-engines.

[0080] Comparative Example 3 differs from Example 1 in that the filament is not reinforced with nanoparticles.

[0081] Pure GH4169 high-temperature alloy with a diameter of 1.2 mm was selected as the wire material, without adding any precursors or nanoparticle reinforcing phases.

[0082] An electric arc feeding additive manufacturing process was performed on the filament, with the following settings: current 300A, voltage 25V, wire feeding speed 5m / min, interlayer temperature controlled at 180℃, deposition rate 4mm / s. Ultrasonic waves were initiated after arc ignition, with an ultrasonic frequency of 45kHz and a power density of 1.4W / cm². 2 The ultrasonic action area covers the liquid-solid two-phase region after the molten pool.

[0083] Multi-directional forging begins when the deposition layer temperature drops to 850℃. The forging frequency is 12 times / minute, with each forging lasting 0.2 seconds. The forging direction alternates between 90° and 0° forging in a 2:1 ratio. The vertical forging pressure is 20MPa, and the horizontal forging pressure is 15MPa. A 25mm diameter H13 hot work die steel forging head with a hardness of HRC50 is used. The forging force loading rate is 75MPa / s, and the unloading rate is 35MPa / s.

[0084] After forging, solution treatment is performed, followed by holding at 1065℃ for 1 hour and air cooling. Then, aging treatment is performed, followed by holding at 720℃ for 8 hours, furnace cooling to 620℃ for 8 hours and air cooling. Finally, stress relief is performed, followed by holding at 650℃ for 3 hours and air cooling to obtain the turbine disk material for aero-engines.

[0085] Performance testing

[0086] Tensile property test: Standard tensile specimens were prepared according to GB / T 228.1-2010 standard. The diameter of the gauge section of the specimen was 5 mm and the gauge length was 25 mm. Tensile tests were conducted at room temperature using a universal testing machine at a tensile rate of 2 mm / min. The yield strength, tensile strength and elongation were recorded. Five specimens were tested in each group and the average value was taken.

[0087] Hardness test: The Vickers hardness tester was used to test according to GB / T 4340.1-2009 standard. The loading force was 98N and the holding time was 15 seconds. Ten test points were randomly selected on the sample surface and the average value was taken. Before the test, the sample surface was ground and polished and the roughness Ra was not greater than 0.1μm.

[0088] Impact toughness test: V-notch impact specimens were prepared according to GB / T 229-2020 standard. The specimen size was 10mm x 10mm x 55mm and the notch depth was 2mm. The test was conducted at room temperature using a pendulum impact testing machine. Three specimens were tested in each group, and the average value was taken. The test was completed within 24 hours before the test after the specimens were processed.

[0089] Fatigue performance testing: The fatigue test was carried out using a rotary bending fatigue testing machine in accordance with the GB / T 4337-2015 standard. The specimen diameter was 7.5 mm, the surface roughness Ra was not greater than 0.4 μm, the stress ratio R was -1, the frequency was 50 Hz, and the test environment temperature was 20 ℃.

[0090] Table 1. Mechanical property test results

[0091] sample Yield strength (MPa) Tensile strength (MPa) Elongation (%) Vickers hardness (HV) Example 1 1245 1485 18.5 425 Example 2 1268 1502 17.8 438 Example 3 1198 1422 19.2 405 Example 4 1289 1518 17.1 445 Example 5 1312 1534 16.8 452 Comparative Example 1 1086 1298 14.2 368 Comparative Example 2 1142 1356 15.8 385 Comparative Example 3 1025 1215 16.5 342

[0092] Table 2. Results of impact toughness and fatigue performance tests

[0093] sample <![CDATA[Impact toughness (J / cm 2 )]]> Fatigue limit (MPa) <![CDATA[Fatigue life (x10 6 times)]]> Example 1 85.2 685 2.85 Example 2 88.6 712 3.12 Example 3 82.1 658 2.58 Example 4 91.3 728 3.35 Example 5 94.7 745 3.52 Comparative Example 1 68.4 542 1.86 Comparative Example 2 72.8 578 2.14 Comparative Example 3 65.2 518 1.72

[0094] As shown in Table 1, the yield strength of Examples 1-5 is significantly higher than that of the comparative examples. The yield strength of Example 5 reaches 1312 MPa, which is 20.8% higher than that of Comparative Example 1, 14.9% higher than that of Comparative Example 2, and 28.0% higher than that of Comparative Example 3. Regarding tensile strength, the tensile strength of the examples is generally in the range of 1420-1540 MPa, while that of the comparative examples is only in the range of 1215-1356 MPa. The tensile strength of Example 5, at 1534 MPa, is 18.2% higher than that of Comparative Example 1. Vickers hardness testing shows that the hardness values ​​of the examples all exceed 400 HV, with Example 5 reaching 452 HV, while the hardness values ​​of the comparative examples are all below 390 HV. This indicates that the synergistic effect of the composite reinforcing phase, ultrasonic assistance, and multi-directional forging significantly improves the strength and hardness of the material. This is due to the combined effect of the dispersion strengthening effect of nanoparticles, ultrasonic grain refinement, and multi-directional forging's defect elimination and improved microstructure density, demonstrating that the technical solution of this invention can significantly improve the static mechanical properties of the material.

[0095] As can be seen from Table 2, the examples show a significant advantage in impact toughness, with Example 5 achieving an impact toughness of 94.7 J / cm. 2 Compared to Comparative Example 1, the fatigue strength was 38.5% higher, compared to Comparative Example 2, it was 30.0% higher, and compared to Comparative Example 3, it was 45.2% higher. Regarding the fatigue limit, Example 5 reached 745 MPa, which was 37.5% higher than Comparative Example 1, 28.9% higher than Comparative Example 2, and 43.8% higher than Comparative Example 3. Fatigue life testing showed that Example 5 achieved a fatigue life of 3.52 x 10⁻⁶ MPa under the same stress level. 6 The results showed that the ultrasonic-assisted process was 89.2% higher than that of Comparative Example 1, 64.5% higher than that of Comparative Example 2, and 104.7% higher than that of Comparative Example 3. This indicates that ultrasonic assistance can effectively refine grains and reduce inclusions, multi-directional forging can eliminate porosity defects and improve the uniformity of the internal structure of the material, and the nano-reinforcing phase can improve the fatigue resistance of the material by preventing crack propagation. This is because the ultrasonic flow effect promotes the stirring of the molten pool and improves the uniformity of element distribution. The compaction effect of multi-directional forging eliminates the micropores and interlayer defects generated during the additive manufacturing process. The nanoparticles, as the second phase reinforcing phase, effectively prevent dislocation movement and crack propagation, demonstrating the significant advantages of the technical route of this invention in improving the dynamic mechanical properties of materials.

[0096] This invention successfully solves the technical problems of coarse microstructure, numerous defects, and unstable performance in traditional additive manufacturing of aero-engine turbine disk materials by synergistically combining ultrasonic-assisted arc wire feeding additive manufacturing, nanoparticle composite reinforcement, and synchronous multi-directional micro-forging. Test results show that, compared to the comparative example, the embodiments of this invention exhibit significant improvements in key indicators such as yield strength, tensile strength, impact toughness, and fatigue performance, fully meeting the stringent requirements for aero-engine turbine disks and providing crucial technical support for the additive manufacturing of key components for high-performance aero-engines.

[0097] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the patent coverage of the present invention.

Claims

1. Use of the electric arc wire feeding process in the production of materials for aeroengine turbine disks, characterized by, The composite wire is prepared by selecting GH4169 high-temperature alloy as a base wire and forming a coating layer of a precursor on the surface of the wire by electroplating. S1. Preparation of the composite wire: GH4169 high-temperature alloy is selected as the base wire, and a coating layer of the precursor is formed on the surface of the wire by electroplating to obtain the composite wire; wherein the content of the precursor accounts for 0.5%-2.0% of the total mass of the composite wire; The precursor comprises TiC nanoparticles and Al2O3 nanoparticles; The TiC nanoparticles are composed of titanium powder and graphite powder, and the coating matrix is a nickel-based binder; S2. Ultrasonic-assisted electric arc wire feeding additive process: the composite wire is subjected to the electric arc wire feeding additive process, and the ultrasonic wave is started after the electric arc is ignited, and the ultrasonic action area covers the liquid / solid two-phase zone at the trailing edge of the molten pool; S3. Synchronous multi-directional micro-forging: when the temperature of the deposited layer decreases to a set temperature, multi-directional forging is started; The multi-directional forging system comprises vertical forging and horizontal forging; S4. Heat treatment process: solid solution treatment, aging treatment and stress relief are performed to obtain the aero-engine turbine disc material; The aero-engine turbine disc material is prepared by performing the ultrasonic-assisted electric arc wire feeding additive process, the ultrasonic action area covering the liquid / solid two-phase zone at the trailing edge of the molten pool, when the temperature of the deposited layer decreases to a set temperature, performing multi-directional micro-forging of vertical forging and horizontal forging alternately, and finally performing heat treatment.

2. Use according to claim 1, characterized in that, In the electric arc wire feeding additive process, the interlayer temperature is controlled to be 150-250 DEG C, and the deposition speed is 3-6 mm / s.

3. Use according to claim 1, characterized in that, In the electric arc wire feeding additive process, the current is 280-350 A, the voltage is 24-28 V, and the wire feeding speed is 4-8 m / min.

4. Use according to claim 1, characterized in that, The ultrasonic frequency of the ultrasonic wave is 40-60 kHz, and the power density is 1.2-1.8 W / cm 2 .

5. The use according to claim 1, characterized in that, The forging frequency of the multi-directional forging is 10-15 times per minute, the duration of each forging is 0.1-0.3 seconds, and the forging direction is alternately performed in the proportion of 2:1 of 90 DEG vertical forging and 0 DEG horizontal forging.

6. Use according to claim 1, characterized in that, The 90 DEG vertical forging pressure of the multi-directional forging system is 15-25 MPa, and the 0 DEG horizontal forging pressure is 10-20 MPa.

7. Use according to claim 1, characterized in that, The forging head material used in the multi-directional forging system is H13 hot work die steel with a hardness of HRC 48-52, the shape of the forging head is a cylinder with a diameter of 20-30 mm, the forging force loading rate is 50-100 MPa / s, and the unloading rate is 20-50 MPa / s.

8. The use according to claim 1, characterized in that, Specifically comprising the following steps: S1. Preparation of the composite wire: GH4169 high-temperature alloy with a diameter of 1.2 mm is selected as the base wire, and a coating layer with a thickness of 5-15 microns of the precursor is formed on the surface of the wire by electroplating to obtain the composite wire, and the content of the precursor accounts for 0.5%-2.0% of the total mass of the composite wire; The precursor is composed of TiC nanoparticles with a particle size of 20-50 nm and Al2O3 nanoparticles with a particle size of 30-80 nm; The TiC nanoparticles are composed of titanium powder with a particle size of less than 5 microns and graphite powder with a particle size of less than 2 microns in a molar ratio of 1:1, and the coating matrix is a nickel-based binder with a thickness of 2-5 microns. S2, ultrasonic assisted electric arc wire feeding additive process: composite wire is subjected to electric arc wire feeding additive process, ultrasonic is started after electric arc is started, ultrasonic action area covers liquid / solid two-phase area of back side of molten pool, interlayer temperature is controlled to be 150-250 DEG C, and deposition speed is 3-6 mm / s; The electric arc wire feeding additive process has current 280-350 A, voltage 24-28 V, and wire feeding speed 4-8 m / min; The ultrasonic frequency is 40-60 kHz, and the power density is 1.2-1.8 W / cm 2 ; S3, synchronous multi-directional micro forging: when the temperature of deposited layer is reduced to 800-900 DEG C, multi-directional forging is started, forging frequency is 10-15 times per minute, each forging duration is 0.1-0.3 seconds, and forging direction is alternately carried out at 90 DEG forging and 0 DEG forging ratio of 2:1; The multi-directional forging system has vertical forging pressure 15-25 MPa and horizontal forging pressure 10-20 MPa; The forging head material used in the multi-directional forging system is H13 hot work die steel, hardness HRC 48-52, the forging head shape is cylinder, diameter 20-30 mm, forging force loading rate 50-100 MPa / s, and unloading rate 20-50 MPa / s; S4. heat treatment process: solid solution treatment is carried out, air cooling is carried out at 1065 DEG C for 1 hour, aging treatment is carried out, air cooling is carried out at 720 DEG C for 8 hours, furnace cooling is carried out to 620 DEG C for 8 hours, air cooling is carried out, stress relief is carried out at 650 DEG C for 3 hours, and air cooling is carried out, to obtain the aero-engine turbine disc material.

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