Laser coaxial wire feeding additive manufacturing method for forming high reflection material

Abstract

The application discloses a laser coaxial wire feeding additive manufacturing method for high-reflection material forming, which comprises the following steps: 1) processing N grooves on the side of the wire made of high-reflection material; 2) while the wire feeding machine feeds the wire from top to bottom, N coaxial lasers emitted by a laser device irradiate the lower part of the wire, the N lasers are distributed on a large-top-small-bottom conical surface, each laser irradiates the groove wall of one groove from top to bottom, and the laser in each groove is reflected on the two groove walls of the groove for multiple times, so that the laser heats multiple parts of the two groove walls of the wire to accelerate the melting of the wire; and 3) the melted wire is accumulated on the workbench layer by layer. Through the groove processing on the side of the wire and the specific arrangement and irradiation mode of the multiple coaxial lasers, the high-reflection material wire is efficiently melted under the laser load and is accumulated and formed on the workbench layer by layer, and the processing efficiency can be effectively improved.

Description

Technical Field

[0001] This invention belongs to the field of additive manufacturing technology, and more specifically, relates to a laser coaxial wire feeding additive manufacturing method for forming highly reflective materials. Background Technology

[0002] Compared to casting, forging and other material manufacturing technologies and subtractive manufacturing technologies such as turning and milling, additive manufacturing technology has advantages such as low material loss, product customization, and no machining. Furthermore, typical high-reflectivity materials, such as copper and aluminum, are widely used in aerospace, biomedicine, and automotive industries due to their excellent electrical conductivity, thermal conductivity, and ductility.

[0003] Coaxial filament technology offers high forming accuracy while balancing cost and deposition efficiency. Common highly reflective materials used in laser welding include aluminum, silver, gold, and some special alloys. These materials have high conductivity and high reflectivity; therefore, during laser welding, they easily reflect the laser beam back, leading to laser energy loss, reduced processing efficiency, and potentially even damage to the laser equipment.

[0004] There are three ways to improve the light absorption rate of typical high-reflectivity materials such as copper and aluminum. The first is to use short-wavelength lasers such as green or blue light to significantly improve the light absorption rate of high-reflectivity metals. Although this method is simple and efficient, such lasers are usually expensive and difficult to implement on a large scale. The second is to add trace alloying elements. For example, adding 0.1% Cr to pure copper directly reduces the reflectivity from 95.2% to 84.0%. The third is to plate a thin layer of low-reflectivity metal on the surface of the high-reflectivity material. However, these two methods of introducing impurities will affect the mechanical properties and microstructure of the material. Summary of the Invention

[0005] In view of the above-mentioned defects or improvement needs of the existing technology, the present invention provides a laser coaxial wire feeding additive manufacturing method for forming highly reflective materials. By improving the shape of the wire, the laser can be reflected multiple times on the surface of the wire, thereby improving the absorption rate of the laser by the wire. In this way, a highly reflective material component with mechanical properties that meet the requirements can be produced by the additive manufacturing method.

[0006] To achieve the above objectives, according to the present invention, a laser coaxial wire feeding additive manufacturing method for forming highly reflective materials is provided, characterized by comprising the following steps:

[0007] 1) N grooves are machined on the side of a filament made of a highly reflective material. The length direction of each groove is consistent with the length direction of the filament, and these grooves are evenly arranged around the center line of the filament, where N≥2.

[0008] 2) While the wire feeding mechanism of the laser coaxial wire feeding additive manufacturing equipment conveys the wire processed in step 1) from top to bottom, the laser device of the laser coaxial wire feeding additive manufacturing equipment emits N coaxial laser beams that irradiate the lower part of the wire. The N laser beams are distributed on a conical surface that is larger at the top and smaller at the bottom, and the center line of the wire is on the same line as the center line of the conical surface. Each laser beam irradiates the wall of a channel from top to bottom, and the laser in each channel is reflected multiple times on the two walls of the channel, so that the laser heats multiple parts of the two walls of the wire to accelerate the melting of the wire.

[0009] 3) The molten filament is stacked layer by layer on the worktable of the laser coaxial filament feeding additive manufacturing equipment to complete the additive manufacturing process.

[0010] Preferably, the channel is a V-shaped channel or a trapezoidal channel.

[0011] Preferably, the groove walls of the filament are roughened to diffusely reflect the laser.

[0012] Preferably, the angle between each laser beam and the filament is equal, and the angle is 50° to 70°.

[0013] Preferably, the diameter of the wire before it exits the channel is 0.8mm to 1.2mm, the wire feeder conveys the wire at a speed of 5mm / s to 30mm / s, the power of each laser beam is 100W to 300W, and the included angle between the two walls of the channel is 50° to 70°.

[0014] Preferably, the highly reactive material is an aluminum alloy or a copper alloy.

[0015] Preferably, the mass fractions of each chemical component of the aluminum alloy are as follows:

[0016] Mg 5.8%-6.8%;

[0017] Mn 0.5%-0.8%;

[0018] Ti 0.02%-0.1%;

[0019] Si≤0.4%;

[0020] Fe ≤ 0.4%;

[0021] Cu≤0.1%;

[0022] Zn≤0.2%;

[0023] The balance is aluminum.

[0024] Preferably, in the copper alloy, the mass fraction of Cu is greater than or equal to 99.9%.

[0025] Preferably, the method for manufacturing the filament is as follows:

[0026] 1) The mass fractions of each chemical component of the aluminum alloy wire are determined as follows:

[0027] Mg 5.8%-6.8%;

[0028] Mn 0.5%-0.8%;

[0029] Ti 0.02%-0.1%;

[0030] Si≤0.4%;

[0031] Fe ≤ 0.4%;

[0032] Cu≤0.1%;

[0033] Zn≤0.2%;

[0034] The balance is aluminum;

[0035] 2) Place the pure aluminum ingot in an induction furnace or resistance furnace and control the temperature at 700℃-750℃. After the pure aluminum ingot melts, add alloying elements Mg, Mn, Ti, Si, Fe, Cu and Zn in the proportion determined in step 1) and smelt. During the smelting process, the melt should be stirred continuously to ensure that the alloying elements are evenly distributed and finally form a molten aluminum alloy. Argon gas should be continuously introduced during the melting of the pure aluminum ingot and the smelting of the alloying elements to avoid oxidation.

[0036] 3) The molten aluminum alloy is poured into a water-cooled mold for semi-continuous casting to form an ingot with a diameter of 100mm-150mm. The ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 450℃-500℃ and the holding time is 8-12 hours.

[0037] 4) Preheat the ingot to 400℃-450℃ to soften it. Then, extrude the ingot into bars with a diameter of 8mm-12mm using an extrusion press. The extrusion ratio is controlled at 10:1-20:1. Graphite lubricant is used during the extrusion process to reduce friction and prevent the ingot from sticking to the die of the extrusion press.

[0038] 5) Pickling is performed on the extruded bars from step 4) to remove the oxide layer and defects on the surface of the bars, and then the surface is blown dry or dried.

[0039] 6) First, draw the pickled bar from step 5) to a diameter of 4mm-6mm, and then perform intermediate annealing. The bar is drawn to a diameter of 4mm-6mm through multiple drawing passes, and the deformation of each pass is controlled at 15%-25%. The intermediate annealing temperature is 300℃-350℃, and the holding time is 1 hour-2 hours.

[0040] 7) Through multiple drawing passes, the bar with a diameter of 4mm-6mm is further drawn to a diameter of 1.5mm-2mm, wherein the deformation amount of each pass is controlled at 10%-20%;

[0041] 8) Draw the bar from step 7) into a wire with a target diameter of 0.8 mm to 1.2 mm;

[0042] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0043] 10) After the wire processed in step 9) is annealed, it is air-cooled. The annealing temperature is 300℃-350℃, and then it is held at that temperature for 1-2 hours.

[0044] 11) Use sandblasting to remove dirt and rust from the surface of the wire to achieve the set surface roughness;

[0045] 12) Ultrasonic cleaning is used to further remove impurities from the surface of the wire. The cleaned wire is then immersed in a chromate passivation solution for passivation treatment, and then dried.

[0046] Preferably, the method for manufacturing the filament is as follows:

[0047] 1) Determine that the mass fraction of Cu in the copper alloy wire is greater than 99.9%;

[0048] 2) Place the high-purity copper ingot in an induction furnace and control the temperature at 1100℃-1200℃. Add an appropriate amount of deoxidizer during the smelting process to reduce the oxygen content in the melt. Inert gas is continuously introduced during the smelting process. The deoxidizer is phosphorus copper, and the mass fraction of phosphorus in the phosphorus copper is 0.03%-0.06%.

[0049] 3) Pour the molten copper liquid into a water-cooled mold for continuous casting to form a copper ingot with a diameter of 100mm-200mm. Then, perform homogenization heat treatment on the copper ingot to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 800℃-850℃ and the holding time is 6 hours-8 hours.

[0050] 4) Preheat the copper ingot to 700℃-800℃ to soften it, and then extrude it into bars with a diameter of 8mm-12mm using an extrusion press. The extrusion ratio is controlled between 10:1 and 20:1.

[0051] 5) Clean the surface of the bar after extrusion in step 4) to remove the oxide layer and defects, then rinse it with clean water and dry it. The surface cleaning is pickling or mechanical polishing.

[0052] 6) Through multiple drawing passes, the bar is gradually drawn from 8mm-12mm to 4mm-6mm. After every 3-5 drawing passes, intermediate annealing is performed at a temperature of 500℃-600℃ and a holding time of 1-2 hours.

[0053] 7) Through multiple drawing passes, the 4mm-6mm bar is further drawn to 1.5mm-2mm. As the diameter of the bar decreases, the drawing speed gradually decreases, and the deformation of each pass is controlled at 10%-20%.

[0054] 8) The bar from step 7) is drawn into a wire with a target diameter of 0.8 mm to 1.2 mm. During this process, the drawing speed is further reduced compared to the drawing speed in step 7).

[0055] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0056] 10) After annealing the wire processed in step 9), air cool it. The annealing temperature is 450℃-550℃ and the holding time is 1 hour-1.5 hours.

[0057] 11) Use sandblasting to remove dirt and rust from the surface of the wire and create a set roughness on the surface of the wire;

[0058] 12) Use a 5%-10% sulfuric acid solution to pickle the surface of the silk material to further remove impurities. After rinsing the surface of the silk material with clean water until it is neutral, dry it and then coat the dried silk material surface with an anti-oxidation grease.

[0059] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects:

[0060] 1) The present invention provides a laser coaxial filament feeding additive manufacturing method for forming highly reflective materials. By processing grooves on the side of the filament and coordinating a specific arrangement and irradiation method of multiple coaxial lasers, the method effectively solves the problems of insufficient melting of highly reflective materials under laser action, low processing efficiency, and damage to the optical system by reflected light. It realizes efficient melting of highly reflective material filaments under laser load and layer-by-layer stacking on the worktable, which can effectively improve processing efficiency.

[0061] 2) The present invention provides a laser coaxial wire feeding additive manufacturing method for forming highly reflective materials. Multiple grooves are machined on the side of the wire, allowing the laser to be reflected multiple times on the two groove walls. Each reflection ensures full contact between the laser and the wire surface, increasing the number and duration of laser-wire interaction, significantly improving laser energy utilization. This allows more laser energy, which originally had low absorption for highly reflective materials, to be converted into heat energy for melting the wire. This effectively solves the problem of laser energy loss due to the high reflectivity of highly reflective materials, improving the material's laser absorption efficiency. Compared to traditional methods, laser utilization can be increased several times, greatly enhancing processing efficiency.

[0062] 3) This invention provides a laser coaxial filament feeding additive manufacturing method for forming highly reflective materials. Multiple coaxial laser beams arranged around the filament irradiate the walls of different channels. Because the channels are uniformly arranged circumferentially around the filament's centerline, the lasers can act evenly on all directions of the filament. This uniform heating method ensures that the filament is heated simultaneously in all areas, resulting in more uniform heating and avoiding localized overheating or incomplete melting. This guarantees the uniformity and stability of the filament melting, thereby improving the quality and fluidity of the melt. It also facilitates the formation of a uniform deposit layer on the worktable, improving the dimensional accuracy and surface quality of the additively manufactured parts, and reducing internal defects and stress concentration problems.

[0063] 4) The present invention provides a laser coaxial wire feeding additive manufacturing method for forming highly reflective materials. By rationally designing the channel structure and the laser irradiation method, the laser is effectively guided and controlled after multiple reflections within the channel. This avoids the reflected light directly irradiating into the laser or other optical components, reducing the risk of damage to the optical system from reflected light, extending the service life of the equipment, reducing equipment maintenance costs and repair time, improving the reliability and stability of the equipment, and ensuring that the additive manufacturing process can be carried out stably for a long time. This is of great significance for large-scale industrial production.

[0064] 5) The present invention provides an effective way to apply highly reflective materials in optical coaxial filament additive manufacturing by using a laser coaxial filament feeding method for forming highly reflective materials. Without changing the chemical composition of the filament, it does not require the use of expensive short-wavelength lasers, nor does it require the addition of other elements or surface coating treatment, thus avoiding the influence of impurities on material properties and broadening the range of materials to be selected for laser additive manufacturing. Attached Figure Description

[0065] Figure 1 This is a flowchart of the present invention;

[0066] Figure 2 This is a top view schematic diagram of the multiple laser beams of the present invention arranged in a ring around the filament;

[0067] Figure 3 This is a schematic diagram illustrating the multiple reflections that occur when a laser beam is irradiated onto a channel in this invention.

[0068] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically:

[0069] 1. First laser beam; 2. Second laser beam; 3. Third laser beam; 4. Fourth laser beam; 5. Fifth laser beam; 6. Sixth laser beam; 7. Wire material; 71. Channel; 11. Incident laser; 12. Reflected laser; 13. First channel wall; 14. Second channel wall; Detailed Implementation

[0070] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0071] Reference Figure 1 , Figure 2 A laser coaxial wire feeding additive manufacturing method for forming highly reflective materials includes the following steps:

[0072] 1) N grooves 71 are machined on the side of a filament 7 made of a highly reflective material. The length direction of each groove 71 is consistent with the length direction of the filament 7, and these grooves 71 are evenly arranged circumferentially around the center line of the filament 7, where N≥2; each groove 71 has a first groove wall and a second groove wall. Common highly reflective materials include brass, copper, aluminum alloy, mirror stainless steel, gold, and silver, etc. These materials usually have high reflectivity, which can reach more than 80%, or even 90%. The highly reflective material of the present invention is preferably an aluminum alloy or a copper alloy.

[0073] 2) While the wire feeding mechanism of the laser coaxial wire feeding additive manufacturing equipment conveys the wire 7 processed in step 1) from top to bottom, the laser device of the laser coaxial wire feeding additive manufacturing equipment emits N coaxial laser beams that irradiate the lower part of the wire 7. The N laser beams are distributed on a conical surface that is larger at the top and smaller at the bottom, and the centerline of the wire 7 is collinear with the centerline of this conical surface. Each laser beam irradiates the wall of a groove 71 from top to bottom, and the laser in each groove 71 undergoes multiple reflections on the two groove walls of the groove 71, allowing the laser to heat multiple parts of the two groove walls of the wire 7 to accelerate the melting of the wire 7; (Refer to...) Figure 2 In one of the channels 71 of the wire 7, the initial incident laser 11 is incident on the first channel wall 13 of the channel 71, and the first reflected laser 12 is incident on the second channel wall 14 and then reflected again. Through such multiple reflections, the melting of the wire 7 is accelerated.

[0074] 3) The molten filament 7 is stacked layer by layer on the worktable of the laser coaxial filament feeding additive manufacturing equipment to complete the additive manufacturing process.

[0075] The laser coaxial wire feeding additive manufacturing equipment employs optical filament coaxial technology. This technology utilizes different beam splitting techniques to change the coupling method between the laser beam and the wire 7, ensuring that the wire 7 is centered and perpendicular to the worktable surface, thus guaranteeing coaxiality between the laser beam and the centerline of the wire 7. Three common types of optical filament coaxial technology are three-beam internal coaxial technology, multi-beam integrated internal coaxial technology, and ring-beam internal coaxial technology. The laser device of this invention can employ one of these three laser coaxial technologies, as long as the emitted laser beam is distributed on the same conical surface. (Refer to...) Figure 1 The laser device of the present invention emits six laser beams, namely the first laser beam 1, the second laser beam 2, the third laser beam 3, the fourth laser beam 4, the fifth laser beam 5, and the sixth laser beam 6.

[0076] In the solid state, highly reflective materials such as aluminum and copper alloys have extremely low absorption rates to conventional 1064nm infrared lasers, only about 7% and 5% respectively, resulting in very low utilization of laser energy. When using low-power lasers for cladding, the laser energy input is insufficient, and the wire 7 cannot be completely melted, making it difficult to effectively clad onto the substrate. However, the reflectivity of highly reflective materials such as aluminum and copper alloys decreases with increasing metal temperature, and the reflectivity drops sharply after the material melts. Taking pure copper as an example, when pure copper is in a molten state, its absorption rate to infrared lasers increases to 30%. Therefore, by maximizing the heat absorption of the wire 7 surface, the surface of the highly reflective material can be rapidly melted, and then interact with the more absorbent molten metal, thus initiating an efficient and stable additive manufacturing process.

[0077] Conventional wires 7 have circular cross-sections. When a laser beam strikes the surface of the wire 7, only a small portion of the energy is used to melt the metal; most of the laser energy is reflected and difficult to reuse. Furthermore, if the angle of the reflected laser is inappropriate, prolonged exposure to the laser can burn out optical components. The method of this invention, by designing suitable channels 71 on the surface of the wire 7, allows the laser beam to be reflected multiple times within the two walls of the channel 71, increasing the utilization rate of the laser. This allows the wire 7 to be fused onto the worktable, and also guides the direction of the reflected laser, preventing the reflected light from directly irradiating the laser.

[0078] The method of the present invention is easy to process, does not require expensive blue or green lasers, and does not introduce external elements. It can realize additive manufacturing of highly reflective materials under near-infrared laser with minimal modification to existing equipment.

[0079] Furthermore, the channel 71 is a V-shaped channel or a trapezoidal channel.

[0080] The design of V-shaped or trapezoidal channels can better realize multiple reflections and energy utilization of the laser within the channel, enhance the heating effect of the laser on the wire 7, improve the quality and efficiency of the melting of the wire 7, and also help guide the direction of the reflected light to better protect the optical system.

[0081] The V-shaped and trapezoidal channels create an angle between the two channel walls. This specific geometry provides a more ideal reflection path for the laser. The two channel walls allow the incident laser to reflect back and forth within the channel, extending the laser's dwell time and effective distance. This increases the contact area between the laser and the surface of the wire 7, allowing more laser energy to be absorbed by the wire 7 and improving the laser absorption efficiency.

[0082] Whether it's a V-shaped or trapezoidal channel, their symmetrical geometry helps to make the laser reflection within the channel 71 more uniform, thereby achieving uniform heating of all parts of the filament 7. When the laser irradiates one wall of the channel 71, the reflected light will irradiate the other wall at a certain angle, thus forming a uniform heat distribution around the filament 7. This avoids local overheating or incomplete melting, improves the uniformity and stability of the filament 7's melting, ensures the quality and fluidity of the melt, and facilitates the formation of a uniform deposit layer on the worktable. This improves the dimensional accuracy and surface quality of additively manufactured parts, reduces internal defects and stress concentration problems, and is of great significance for manufacturing high-quality additively manufactured products.

[0083] Furthermore, the groove walls of the channel 71 of the filament 7 are roughened to diffusely reflect the laser. Roughening the channel 71 of the filament 7 aims to change the way the laser is reflected on the surface of the channel 71, further improving the utilization rate of the laser and the absorption rate of the laser by the filament 7, while reducing the risk of damage to the optical system from reflected light and enhancing the stability and safety of the additive manufacturing process.

[0084] By roughening the channel 71, the originally smooth surface of the filament 7 becomes rough and uneven, disrupting the specular reflection that might occur on a smooth surface and instead causing diffuse reflection. Diffuse reflection scatters the laser in all directions, increasing the probability and area of ​​contact between the laser and the surface of the filament 7. This allows more laser energy to be absorbed by the filament 7, effectively improving its absorption rate. Especially for highly reflective materials, this treatment significantly improves their laser absorption performance, further enhancing the melting efficiency and quality of the filament 7, and providing stronger support for the application of highly reflective materials in optical coaxial technology.

[0085] The roughened surface of channel 71 causes the reflected light to be dispersed into multiple weaker beams scattered in different directions, rather than being a concentrated, intense beam. This dispersed reflected light energy is greatly reduced, minimizing the risk of damage to the optical system and preventing damage that could occur if the reflected light directly hits the laser or other sensitive optical components, such as burning out optical devices or affecting the normal operation of the laser. Simultaneously, diffuse reflection also disperses the reflected light in space, reducing interference with the surrounding environment and other equipment, improving the safety and reliability of the additive manufacturing equipment, ensuring stable operation over long periods, and reducing equipment maintenance and costs caused by reflected light damage.

[0086] The roughening process can be adjusted and optimized according to different highly reflective materials and specific additive manufacturing process requirements. By controlling the size and distribution of roughness, precise control over laser absorption rate and reflection characteristics can be achieved. This allows the method of the present invention to better adapt to different types of highly reflective materials and different coaxial filament technology parameters, exhibiting strong flexibility and adaptability. It can meet the diverse needs of aerospace, biomedical, and other fields for high-precision, high-performance additive manufacturing products, promoting the application and development of highly reflective materials in a wider range of fields.

[0087] The V-shaped channel allows the laser to reflect multiple times on its two walls, ensuring full contact between the laser and the wire 7 with each reflection, increasing the absorption opportunity. Compared to the specular reflection of a smooth surface, the diffuse reflection and long working distance of the V-shaped channel significantly improve laser utilization, providing strong support for the efficient processing of highly reflective materials. Specific advantages are as follows:

[0088] Furthermore, the angle between each laser beam and the wire 7 is equal, and the angle is 50° to 70°. This ensures that the laser can irradiate the groove of the wire 7 at the optimal incident angle, realizing the effective utilization of laser energy and uniform heating of the wire 7, while avoiding the adverse effects of reflected light on the optical system.

[0089] Extensive experimental research and theoretical analysis have revealed that when the angle between the laser and the wire 7 is within the range of 50°-70°, the laser can strike the wall of the channel 71 at a more suitable angle, optimizing the reflection path and the number of interactions within the channel 71. Within this angle range, the laser beam can interact more fully with the surface of the channel 71, resulting in less energy loss after each reflection. This maximizes the transfer of laser energy to the wire 7, improving its absorption efficiency and accelerating the melting rate. This enhances the efficiency and quality of additive manufacturing. Compared to other angle ranges, this range better leverages the heating effect of the laser, achieving higher energy utilization efficiency. This is significant for reducing production costs and improving production efficiency.

[0090] The equal angle arrangement ensures that each laser beam heats the filament 7 uniformly. Because multiple laser beams are evenly distributed around the filament 7, and each beam has the same angle with the filament 7, the laser heating effect on the filament 7 is balanced in all directions, avoiding localized overheating or underheating caused by different laser angles. This uniform heating method ensures that the filament 7 is heated simultaneously in the circumferential direction, resulting in more uniform heating, improved uniformity and stability of the filament 7's melting, guaranteed melt quality and fluidity, and facilitates the formation of a uniform deposit layer on the worktable. This improves the dimensional accuracy and surface quality of additively manufactured parts, reduces internal defects and stress concentration problems, and enhances product performance and reliability.

[0091] An angle range of 50°-70° is beneficial for controlling the direction of reflected light, ensuring it reflects and propagates along a predetermined path, and preventing it from directly returning to the laser or other optical components. By appropriately selecting and controlling this angle, reflected light can be guided to a relatively safe direction, further reducing the risk of damage to the optical system. It also helps reduce interference from reflected light within the working area, improving the stability and safety of the additive manufacturing process. Furthermore, a uniform angle arrangement makes the distribution of reflected light more even and controllable, which is beneficial for the optical path design and optimization of the entire manufacturing system, improving the integration and performance of the equipment.

[0092] Furthermore, the diameter of the wire 7 before it is processed into the groove 71 is 0.8mm to 1.2mm, the speed at which the wire feeder conveys the wire 7 is 5mm / s to 30mm / s, the power of each laser beam is 100W to 300W, and the included angle between the two walls of the groove 71 is 50° to 70°.

[0093] By optimizing these parameters, the best utilization of laser energy can be achieved, improving processing efficiency and quality while reducing the risk of damage to the optical system.

[0094] By limiting the laser power to a reasonable range, it can be ensured that the laser beam has sufficient energy to melt the filament 7, while avoiding overheating or burning of the material due to excessive power. Appropriate laser power ensures that the filament 7 melts uniformly under laser action, improving the quality and flowability of the melt, thereby enhancing the dimensional accuracy and surface quality of the additively manufactured parts.

[0095] The wire feeding speed is controlled to match the laser power, ensuring that the wire 7 remains within the laser beam's effective area for sufficient time to absorb laser energy. An excessively fast feeding speed will result in incomplete melting of the wire 7, while an excessively slow speed may cause localized overheating. Precise control of the wire feeding speed ensures continuous and uniform melting of the wire 7, guaranteeing a stable supply of melt and improving production efficiency and part quality.

[0096] By controlling the diameter of wire 7 within a suitable range, it can be ensured that wire 7 can be completely melted during subsequent processing.

[0097] The included angle between the two walls of channel 71 has a significant impact on the laser reflection path and energy distribution. By rationally designing the included angle, multiple reflections of the laser within channel 71 can be achieved, ensuring a uniform distribution of laser energy on the surface of wire 7. This not only improves laser utilization but also avoids localized overheating or incomplete melting, ensuring the uniformity and stability of wire 7 melting and reducing internal defects and stress concentration issues in the parts.

[0098] In summary, this invention provides precise parameter guidance for additive manufacturing of highly reflective materials in coaxial optical filament technology by specifying key process parameters such as the diameter of the filament 7, the filament feeding speed, the laser power, and the groove wall angle. Optimization and rational combination of these parameters can effectively improve the utilization rate of laser energy, ensure uniform melting and stable processing of the filament 7, thereby improving the quality and production efficiency of additively manufactured parts, while reducing the risk of damage to the optical system.

[0099] Furthermore, the mass fractions of each chemical component of the aluminum alloy are as follows:

[0100] Mg 5.8%-6.8%;

[0101] Mn 0.5%-0.8%;

[0102] Ti 0.02%-0.1%;

[0103] Si≤0.4%;

[0104] Fe ≤ 0.4%;

[0105] Cu≤0.1%;

[0106] Zn≤0.2%;

[0107] The balance is aluminum.

[0108] Strict control of chemical composition is crucial to ensuring the stability of aluminum alloy performance. By specifying the exact content ranges of major alloying elements such as Mg, Mn, and Ti, as well as impurity elements such as Si, Fe, Cu, and Zn, it is possible to guarantee that aluminum alloys possess excellent comprehensive properties in terms of strength, toughness, corrosion resistance, and thermal stability, meeting the requirements for wire materials in additive manufacturing processes. Stable material properties help improve the quality and reliability of additively manufactured parts, reduce manufacturing defects and product performance differences caused by fluctuations in material properties, and are of great significance for realizing the large-scale industrial production of aluminum alloy parts.

[0109] Different elements and their contents have a significant impact on the light absorption and reflection characteristics of aluminum alloys. For example, an appropriate amount of Mg can increase the reflectivity of aluminum alloys, while Mn has a certain promoting effect on light absorption. By precisely controlling the content of each element, the balance between laser absorption and reflection of aluminum alloys can be optimized to a certain extent. This ensures that in coaxial laser filament technology, sufficient laser absorption rate is achieved for rapid melting, while avoiding excessive reflectivity that could damage the optical system. This improves the effective utilization rate of laser energy, enables a highly efficient additive manufacturing process, and further enhances the manufacturing quality and efficiency of aluminum alloy parts.

[0110] Furthermore, in the copper alloy, the mass fraction of Cu is greater than or equal to 99.9%. High-purity copper alloys exhibit relatively stable reflectivity and absorptivity under laser irradiation, ensuring stable laser energy input and uniform melting of the wire 7. This reduces processing instability caused by fluctuations in material composition, improves the consistency and reliability of the additive manufacturing process, guarantees product quality stability, and reduces production costs and defect rates. High-purity copper alloys are better suited to specific additive manufacturing process requirements, such as processing stability and weldability at high temperatures. During additive manufacturing, the high-purity copper alloy wire 7 maintains good plasticity and toughness at high temperatures, facilitating melting and flow to form a uniform and dense deposited layer.

[0111] Furthermore, the manufacturing method of the filament 7 is as follows:

[0112] 1) The mass fractions of each chemical component of the aluminum alloy wire 7 are determined as follows:

[0113] Mg 5.8%-6.8%;

[0114] Mn 0.5%-0.8%;

[0115] Ti 0.02%-0.1%;

[0116] Si≤0.4%;

[0117] Fe ≤ 0.4%;

[0118] Cu≤0.1%;

[0119] Zn≤0.2%;

[0120] The balance is aluminum;

[0121] 2) Place the pure aluminum ingot in an induction furnace or resistance furnace and control the temperature at 700℃-750℃. After the pure aluminum ingot melts, add alloying elements Mg, Mn, Ti, Si, Fe, Cu and Zn in the proportion determined in step 1) and smelt. During the smelting process, the melt should be stirred continuously to ensure that the alloying elements are evenly distributed and finally form a molten aluminum alloy. Argon gas should be continuously introduced during the melting of the pure aluminum ingot and the smelting of the alloying elements to avoid oxidation.

[0122] 3) The molten aluminum alloy is poured into a water-cooled mold for semi-continuous casting to form an ingot with a diameter of 100mm-150mm. The ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 450℃-500℃ and the holding time is 8-12 hours.

[0123] 4) Preheat the ingot to 400℃-450℃ to soften it. Then, extrude the ingot into bars with a diameter of 8mm-12mm using an extrusion press. The extrusion ratio is controlled at 10:1-20:1. Graphite lubricant is used during the extrusion process to reduce friction and prevent the ingot from sticking to the die of the extrusion press.

[0124] 5) Pickling is performed on the extruded bars from step 4) to remove the oxide layer and defects on the surface of the bars, and then the surface is blown dry or dried.

[0125] 6) First, draw the pickled bar from step 5) to a diameter of 4mm-6mm, and then perform intermediate annealing. The bar is drawn to a diameter of 4mm-6mm through multiple drawing passes, and the deformation of each pass is controlled at 15%-25%. The intermediate annealing temperature is 300℃-350℃, and the holding time is 1 hour-2 hours.

[0126] 7) Through multiple drawing passes, the bar with a diameter of 4mm-6mm is further drawn to a diameter of 1.5mm-2mm, wherein the deformation amount of each pass is controlled at 10%-20%;

[0127] 8) Draw the bar from step 7) into a wire 7 with a target diameter of 1.2 mm;

[0128] 9) N grooves are machined on the side of the wire 7, the length direction of each groove is consistent with the length direction of the wire 7, and these grooves are evenly arranged around the center line of the wire 7.

[0129] 10) After annealing the wire material 7 processed in step 9), air cool it. The annealing temperature is 300℃-350℃, and then it is kept at that temperature for 1-2 hours.

[0130] 11) Use sandblasting to remove dirt and rust from the surface of wire 7 so that the surface of wire 7 reaches the set roughness;

[0131] 12) Ultrasonic cleaning is used to further remove impurities from the surface of the wire 7. Then, the cleaned wire 7 is immersed in chromate passivation solution for passivation treatment and then dried.

[0132] The manufacturing method for aluminum alloy wire 7 involves meticulously designed and optimized process steps and parameter ranges, enabling efficient production and stable supply of aluminum alloy wire 7. For example, homogenized heat treatment and appropriate extrusion ratios can improve material processing efficiency and reduce scrap rates during production; multi-pass drawing and intermediate annealing processes ensure dimensional accuracy and performance uniformity of wire 7 during the drawing process, reducing production costs; surface treatment processes can extend the service life of wire 7 and reduce maintenance costs. Overall, this complete manufacturing process helps improve the production efficiency and cost-effectiveness of aluminum alloy wire 7, providing an economically feasible raw material solution for the large-scale industrial application of coaxial additive manufacturing technology for optical fibers, and promoting the sustainable development of related industries.

[0133] Furthermore, the manufacturing method of the filament 7 is as follows:

[0134] 1) Determine that the mass fraction of Cu in the copper alloy wire 7 is greater than 99.9%;

[0135] 2) Place the high-purity copper ingot in an induction furnace and control the temperature at 1100℃-1200℃. Add an appropriate amount of deoxidizer during the smelting process to reduce the oxygen content in the melt. Inert gas is continuously introduced during the smelting process. The deoxidizer is phosphorus copper, and the mass fraction of phosphorus in the phosphorus copper is 0.03%-0.06%.

[0136] 3) Pour the molten copper liquid into a water-cooled mold for continuous casting to form a copper ingot with a diameter of 100mm-200mm. Then, perform homogenization heat treatment on the copper ingot to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 800℃-850℃ and the holding time is 6 hours-8 hours.

[0137] 4) Preheat the copper ingot to 700℃-800℃ to soften it, and then extrude it into bars with a diameter of 8mm-12mm using an extrusion press. The extrusion ratio is controlled between 10:1 and 20:1.

[0138] 5) Clean the surface of the bar after extrusion in step 4) to remove the oxide layer and defects, then rinse it with clean water and dry it. The surface cleaning is pickling or mechanical polishing.

[0139] 6) Through multiple drawing passes, the bar is gradually drawn from 8mm-12mm to 4mm-6mm. After every 3-5 drawing passes, intermediate annealing is performed at a temperature of 500℃-600℃ and a holding time of 1-2 hours.

[0140] 7) Through multiple drawing passes, the 4mm-6mm bar is further drawn to 1.5mm-2mm. As the diameter of the bar decreases, the drawing speed gradually decreases, and the deformation of each pass is controlled at 10%-20%.

[0141] 8) The bar from step 7) is drawn into a wire 7 with a target diameter of 1.2 mm. During this process, the drawing speed is further reduced compared to the drawing speed in step 7).

[0142] 9) N grooves are machined on the side of the wire 7, the length direction of each groove is consistent with the length direction of the wire 7, and these grooves are evenly arranged around the center line of the wire 7.

[0143] 10) After annealing the wire material 7 processed in step 9), air cool it. The annealing temperature is 450℃-550℃ and the holding time is 1 hour-1.5 hours.

[0144] 11) Use sandblasting to remove dirt and rust from the surface of wire 7 and create a set roughness on the surface of wire 7;

[0145] 12) Use a 5%-10% sulfuric acid solution to pickle the surface of the filament 7 to further remove impurities from the surface of the filament 7. After rinsing the surface of the filament 7 with clean water until it is neutral, dry it and coat the dried filament 7 with an anti-oxidation grease.

[0146] This manufacturing method, from the selection of high-purity copper ingots to deoxidation and inert gas protection during smelting, and then to homogenization heat treatment, revolves around ensuring the high purity and performance stability of the copper alloy. These measures effectively reduce the impurity content and defects in the copper alloy, improve the electrical and thermal conductivity and mechanical properties of the material, and ensure that the copper alloy wire 7 has good processing performance and stable melting behavior during additive manufacturing.

[0147] The groove shape on the side of the copper alloy wire 7 is achieved through precision machine tool machining, followed by a series of surface treatment processes such as annealing, sandblasting, pickling, and anti-oxidation treatment. This optimizes the shape accuracy and surface quality of the copper alloy wire 7. Precise machining of the groove shape ensures effective laser reflection and energy utilization on the surface of the wire 7, while surface treatment improves the uniformity and cleanliness of the surface roughness, enhances the diffuse reflection effect of the laser, and reduces the harmful effects of reflected light. Simultaneously, the anti-oxidation treatment helps maintain the chemical stability and good machinability of the wire 7 surface, extending its service life and improving the efficiency and product quality of the additive manufacturing process.

[0148] Example 1

[0149] 1) The mass fractions of each chemical component of the aluminum alloy wire are determined as follows:

[0150] Mg 5.8%;

[0151] Mn 0.5%;

[0152] Ti 0.02%;

[0153] Si 0.35%;

[0154] Fe 0.3%;

[0155] Cu 0.05%;

[0156] Zn 0.1%;

[0157] The balance is aluminum;

[0158] 2) Place the pure aluminum ingot in an induction furnace and control the temperature at 700℃. After the pure aluminum ingot melts, add alloying elements Mg, Mn, Ti, Si, Fe, Cu and Zn in the proportion determined in step 1) and smelt. During the smelting process, the melt should be stirred continuously to ensure that the alloying elements are evenly distributed and finally form a molten aluminum alloy. Argon gas should be continuously introduced during the melting of the pure aluminum ingot and the smelting of the alloying elements to avoid oxidation.

[0159] 3) The molten aluminum alloy is poured into a water-cooled mold for semi-continuous casting to form an ingot with a diameter of 100 mm. The ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 450℃ and the holding time is 12 hours.

[0160] 4) Preheat the ingot to 400℃ to soften it, and then extrude it into bars with a diameter of 8mm using an extrusion press. The extrusion ratio is controlled at 10:1. Graphite lubricant is used during the extrusion process to reduce friction and prevent the ingot from sticking to the die of the extrusion press.

[0161] 5) Pickling is performed on the extruded bars from step 4) to remove the oxide layer and defects on the surface of the bars, and then the surface is blown dry or dried.

[0162] 6) First, draw the pickled bar from step 5) to a diameter of 4mm, and then perform intermediate annealing. The bar is drawn to a diameter of 4mm through multiple drawing passes, and the deformation of each pass is controlled at 15%. The intermediate annealing temperature is 300℃ and the holding time is 2 hours.

[0163] 7) Through multiple drawing passes, the 4mm diameter bar is further drawn to a diameter of 1.5mm, with the deformation amount of each pass controlled at 10%.

[0164] 8) Draw the bar from step 7) into a wire with a target diameter of 0.8 mm;

[0165] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0166] 10) After the wire processed in step 9) is annealed, it is air-cooled. The annealing temperature is 300℃, and then it is held at that temperature for 2 hours.

[0167] 11) Use sandblasting to remove dirt and rust from the surface of the wire to achieve the set surface roughness;

[0168] 12) Ultrasonic cleaning is used to further remove impurities from the surface of the wire. The cleaned wire is then immersed in a chromate passivation solution for passivation treatment, and then dried.

[0169] Example 2

[0170] 1) The mass fractions of each chemical component of the aluminum alloy wire are determined as follows:

[0171] Mg 6.8%;

[0172] Mn 0.8%;

[0173] Ti 0.1%;

[0174] Si 0.3%;

[0175] Fe 0.25%;

[0176] Cu 0.08%;

[0177] Zn 0.015%;

[0178] The balance is aluminum;

[0179] 2) Place the pure aluminum ingot in an induction furnace and control the temperature at 750℃. After the pure aluminum ingot melts, add alloying elements Mg, Mn, Ti, Si, Fe, Cu and Zn in the proportion determined in step 1) and smelt. During the smelting process, the melt should be stirred continuously to ensure that the alloying elements are evenly distributed and finally form a molten aluminum alloy. Argon gas should be continuously introduced during the melting of the pure aluminum ingot and the smelting of the alloying elements to avoid oxidation.

[0180] 3) The molten aluminum alloy is poured into a water-cooled mold for semi-continuous casting to form an ingot with a diameter of 150 mm. The ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 500℃ and the holding time is 8 hours.

[0181] 4) Preheat the ingot to 450℃ to soften it, and then extrude it into a bar with a diameter of 12mm using an extrusion press. The extrusion ratio is controlled at 20:1. Graphite lubricant is used during the extrusion process to reduce friction and prevent the ingot from sticking to the die of the extrusion press.

[0182] 5) Pickling is performed on the extruded bars from step 4) to remove the oxide layer and defects on the surface of the bars, and then the surface is blown dry or dried.

[0183] 6) First, draw the pickled bar from step 5) to a diameter of 6mm, and then perform intermediate annealing. The bar is drawn to a diameter of 6mm through multiple drawing passes, and the deformation of each pass is controlled at 25%. The intermediate annealing temperature is 350℃ and the holding time is 1 hour.

[0184] 7) Through multiple drawing passes, the 6mm diameter bar is further drawn to a diameter of 2mm, with the deformation amount in each pass controlled at 20%.

[0185] 8) Draw the bar from step 7) into a wire with a target diameter of 1.2 mm;

[0186] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0187] 10) After the wire processed in step 9) is annealed, it is air-cooled. The annealing temperature is 350℃, and then it is held at that temperature for 1 hour.

[0188] 11) Use sandblasting to remove dirt and rust from the surface of the wire to achieve the set surface roughness;

[0189] 12) Ultrasonic cleaning is used to further remove impurities from the surface of the wire. The cleaned wire is then immersed in a chromate passivation solution for passivation treatment, and then dried.

[0190] Example 3

[0191] 1) The mass fractions of each chemical component of the aluminum alloy wire are determined as follows:

[0192] Mg 6.2%;

[0193] Mn 0.6%;

[0194] Ti 0.08%;

[0195] Si 0.4%;

[0196] Fe 0.4%;

[0197] Cu 0.1%;

[0198] Zn 0.2%;

[0199] The balance is aluminum;

[0200] 2) Place the pure aluminum ingot in a resistance furnace and control the temperature at 720℃. After the pure aluminum ingot melts, add alloying elements Mg, Mn, Ti, Si, Fe, Cu and Zn in the proportion determined in step 1) and smelt. During the smelting process, the melt should be stirred continuously to ensure that the alloying elements are evenly distributed and finally form a molten aluminum alloy. Argon gas should be continuously introduced during the melting of the pure aluminum ingot and the smelting of the alloying elements to avoid oxidation.

[0201] 3) The molten aluminum alloy is poured into a water-cooled mold for semi-continuous casting to form an ingot with a diameter of 120 mm. The ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 470℃ and the holding time is 10 hours.

[0202] 4) Preheat the ingot to 420℃ to soften it, and then extrude it into bars with a diameter of 10mm using an extrusion press. The extrusion ratio is controlled at 15:1. Graphite lubricant is used during the extrusion process to reduce friction and prevent the ingot from sticking to the die of the extrusion press.

[0203] 5) Pickling is performed on the extruded bars from step 4) to remove the oxide layer and defects on the surface of the bars, and then the surface is blown dry or dried.

[0204] 6) First, draw the pickled bar from step 5) to a diameter of 5mm, and then perform intermediate annealing. The bar is drawn to a diameter of 5mm through multiple drawing passes, and the deformation of each pass is controlled at 20%. The intermediate annealing temperature is 320℃ and the holding time is 1.5 hours.

[0205] 7) Through multiple drawing passes, the 5mm diameter bar is further drawn to a diameter of 1.8mm, with the deformation amount of each pass controlled at 15%.

[0206] 8) Draw the bar from step 7) into a wire with a target diameter of 1 mm;

[0207] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0208] 10) After the wire processed in step 9) is annealed, it is air-cooled. The annealing temperature is 320℃, and then it is held at that temperature for 1.5 hours.

[0209] 11) Use sandblasting to remove dirt and rust from the surface of the wire to achieve the set surface roughness;

[0210] 12) Ultrasonic cleaning is used to further remove impurities from the surface of the wire. The cleaned wire is then immersed in a chromate passivation solution for passivation treatment, and then dried.

[0211] Example 4

[0212] The method for manufacturing the filament is as follows:

[0213] 1) Determine that the mass fraction of Cu in the copper alloy wire is 99.95%;

[0214] 2) Place the high-purity copper ingot in an induction furnace and control the temperature at 1100℃. Add an appropriate amount of deoxidizer during the smelting process to reduce the oxygen content in the melt. Inert gas is continuously introduced during the smelting process. The deoxidizer is phosphorus copper with a phosphorus mass fraction of 0.03%.

[0215] 3) The molten copper liquid is poured into a water-cooled mold for continuous casting to form a copper ingot with a diameter of 100mm. The copper ingot is then subjected to homogenization heat treatment to eliminate component segregation and internal stress. The homogenization heat treatment temperature is 800℃ and the holding time is 8 hours.

[0216] 4) Preheat the copper ingot to 700℃ to soften it, and then extrude it into bars with a diameter of 8mm using an extruder. The extrusion ratio is controlled at 10:1.

[0217] 5) Clean the surface of the bar after extrusion in step 4) to remove the oxide layer and defects, then rinse it with clean water and dry it. The surface cleaning is mechanical polishing.

[0218] 6) The bar is gradually drawn from 8mm to 4mm through multiple drawing passes. After every 3 drawing passes, intermediate annealing is performed at a temperature of 500℃ for 2 hours.

[0219] 7) Through multiple drawing passes, the 4mm bar is further drawn to 1.5mm. As the diameter of the bar decreases, the drawing speed gradually decreases, and the deformation in each pass is controlled at 10%.

[0220] 8) The bar from step 7) is drawn into a wire with a target diameter of 0.8 mm. During this process, the drawing speed is further reduced compared to the drawing speed in step 7).

[0221] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0222] 10) After annealing the wire processed in step 9), air cool it. The annealing temperature is 450℃ and the holding time is 1.5 hours.

[0223] 11) Use sandblasting to remove dirt and rust from the surface of the wire and create a set roughness on the surface of the wire;

[0224] 12) Use a 5% sulfuric acid solution to pickle the surface of the silk material to further remove impurities. After rinsing the surface of the silk material with clean water until it is neutral, dry it and then coat the dried silk material surface with an anti-oxidation grease.

[0225] Example 5

[0226] The method for manufacturing the filament is as follows:

[0227] 1) Determine that the mass fraction of Cu in the copper alloy wire is 99.999%;

[0228] 2) Place the high-purity copper ingot in an induction furnace and control the temperature at 1200℃. Add an appropriate amount of deoxidizer during the smelting process to reduce the oxygen content in the melt. Inert gas is continuously introduced during the smelting process. The deoxidizer is phosphorus copper with a phosphorus mass fraction of 0.06%.

[0229] 3) Pour the molten copper liquid into a water-cooled mold for continuous casting to form a copper ingot with a diameter of 200mm. Then, perform homogenization heat treatment on the copper ingot to eliminate component segregation and internal stress. The homogenization heat treatment temperature is 850℃ and the holding time is 6 hours.

[0230] 4) Preheat the copper ingot to 800℃ to soften it, and then extrude it into bars with a diameter of 12mm using an extruder. The extrusion ratio is controlled at 20:1.

[0231] 5) Clean the surface of the bar after extrusion in step 4) to remove the oxide layer and defects, then rinse it with clean water and dry it. The surface cleaning is pickling.

[0232] 6) The bar is gradually drawn from 12mm to 6mm through multiple drawing passes. After every 5 drawing passes, intermediate annealing is performed at a temperature of 600℃ and a holding time of 1 hour.

[0233] 7) Through multiple drawing passes, the 6mm bar is further drawn to 2mm. As the diameter of the bar decreases, the drawing speed gradually decreases, and the deformation in each pass is controlled at 20%.

[0234] 8) The bar from step 7) is drawn into a wire with a target diameter of 1.2 mm. During this process, the drawing speed is further reduced compared to the drawing speed in step 7).

[0235] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0236] 10) After annealing the wire material processed in step 9), air cool it. The annealing temperature is 550℃ and the holding time is 1 hour.

[0237] 11) Use sandblasting to remove dirt and rust from the surface of the wire and create a set roughness on the surface of the wire;

[0238] 12) Use a 10% sulfuric acid solution to pickle the surface of the silk material to further remove impurities. After rinsing the surface of the silk material with clean water until it is neutral, dry it and then coat the dried silk material surface with an anti-oxidation grease.

[0239] Example 6

[0240] The method for manufacturing the filament is as follows:

[0241] 1) Determine that the mass fraction of Cu in the copper alloy wire is 99.995%;

[0242] 2) Place the high-purity copper ingot in an induction furnace and control the temperature at 1150℃. Add an appropriate amount of deoxidizer during the smelting process to reduce the oxygen content in the melt. Inert gas is continuously introduced during the smelting process. The deoxidizer is phosphorus copper with a phosphorus mass fraction of 0.04%.

[0243] 3) The molten copper liquid is poured into a water-cooled mold for continuous casting to form a copper ingot with a diameter of 150mm. The copper ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 820℃ and the holding time is 7 hours.

[0244] 4) Preheat the copper ingot to 750℃ to soften it, and then extrude it into bars with a diameter of 10mm using an extruder. The extrusion ratio is controlled at 15:1.

[0245] 5) Clean the surface of the bar after extrusion in step 4) to remove the oxide layer and defects, then rinse it with clean water and dry it. The surface cleaning is pickling or mechanical polishing.

[0246] 6) The bar is gradually drawn from 10mm to 5mm through multiple drawing passes. After every 4 drawing passes, intermediate annealing is performed at a temperature of 550℃ for 1.5 hours.

[0247] 7) Through multiple drawing passes, the 5mm bar is drawn to 1.8mm. As the diameter of the bar decreases, the drawing speed gradually decreases, and the deformation in each pass is controlled at 15%.

[0248] 8) The bar from step 7) is drawn into a wire with a target diameter of 1.0 mm. During this process, the drawing speed is further reduced compared to the drawing speed in step 7).

[0249] 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire.

[0250] 10) After annealing the wire material processed in step 9), air cool it. The annealing temperature is 500℃ and the holding time is 1.2 hours.

[0251] 11) Use sandblasting to remove dirt and rust from the surface of the wire and create a set roughness on the surface of the wire;

[0252] 12) Use an 8% sulfuric acid solution to pickle the surface of the silk material to further remove impurities. After rinsing the surface of the silk material with clean water until it is neutral, dry it and then coat the dried silk material surface with an anti-oxidation grease.

[0253] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A laser coaxial wire feeding additive manufacturing method for forming highly reflective materials, characterized in that, Includes the following steps: 1) N grooves are machined on the side of a filament made of a highly reflective material. The length direction of each groove is consistent with the length direction of the filament, and these grooves are evenly arranged around the center line of the filament, where N≥2. 2) While the wire feeding mechanism of the laser coaxial wire feeding additive manufacturing equipment conveys the wire processed in step 1) from top to bottom, the laser device of the laser coaxial wire feeding additive manufacturing equipment emits N coaxial laser beams that irradiate the lower part of the wire. The N laser beams are distributed on a conical surface that is larger at the top and smaller at the bottom, and the center line of the wire is on the same line as the center line of the conical surface. Each laser beam irradiates the wall of a channel from top to bottom, and the laser in each channel is reflected multiple times on the two walls of the channel, so that the laser heats multiple parts of the two walls of the wire to accelerate the melting of the wire. 3) The molten filament is stacked layer by layer on the worktable of the laser coaxial filament feeding additive manufacturing equipment to complete the additive manufacturing process.

2. The laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, The channel is a V-shaped channel or a trapezoidal channel.

3. The laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, The groove walls of the filament are roughened to diffusely reflect the laser light.

4. The laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, Each laser beam makes an equal angle with the wire, ranging from 50° to 70°.

5. The laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, The diameter of the wire before it is processed into the channel is 0.8mm~1.2mm, the wire feeder conveys the wire at a speed of 5mm / s~30mm / s, the power of each laser beam is 100W~300W, and the included angle between the two walls of the channel is 50°~70°.

6. The laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, The highly reactive material is an aluminum alloy or a copper alloy.

7. A laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 6, characterized in that, The mass fractions of each chemical component in the aluminum alloy are as follows: Mg 5.8%-6.8%; Mn 0.5%-0.8%; Ti 0.02%-0.1%; Si≤0.4%; Fe≤0.4%; Cu≤0.1%; Zn≤0.2%; The balance is aluminum.

8. A laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 6, characterized in that, In the copper alloy, the mass fraction of Cu is greater than or equal to 99.9%.

9. A laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, The method for manufacturing the filament is as follows: 1) The mass fractions of each chemical component of the aluminum alloy wire are determined as follows: Mg 5.8%-6.8%; Mn 0.5%-0.8%; Ti 0.02%-0.1%; Si≤0.4%; Fe≤0.4%; Cu≤0.1%; Zn≤0.2%; The balance is aluminum; 2) Place the pure aluminum ingot in an induction furnace or resistance furnace and control the temperature at 700℃-750℃. After the pure aluminum ingot melts, add alloying elements Mg, Mn, Ti, Si, Fe, Cu and Zn in the proportion determined in step 1) and smelt. During the smelting process, the melt should be stirred continuously to ensure that the alloying elements are evenly distributed and finally form a molten aluminum alloy. Argon gas should be continuously introduced during the melting of the pure aluminum ingot and the smelting of the alloying elements to avoid oxidation. 3) The molten aluminum alloy is poured into a water-cooled mold for semi-continuous casting to form an ingot with a diameter of 100mm-150mm. The ingot is then subjected to homogenization heat treatment to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 450℃-500℃ and the holding time is 8-12 hours. 4) Preheat the ingot to 400℃-450℃ to soften it. Then, extrude the ingot into bars with a diameter of 8mm-12mm using an extrusion press. The extrusion ratio is controlled at 10:1-20:

1. Graphite lubricant is used during the extrusion process to reduce friction and prevent the ingot from sticking to the die of the extrusion press. 5) Pickling is performed on the extruded bars from step 4) to remove the oxide layer and defects on the surface of the bars, and then the surface is blown dry or dried. 6) First, draw the pickled bar from step 5) to a diameter of 4 mm - 6 mm, and then perform intermediate annealing. The bar is drawn to a diameter of 4 mm - 6 mm through multiple drawing passes, and the deformation of each pass is controlled at 15% - 25%. The intermediate annealing temperature is 300℃ - 350℃, and the holding time is 1 hour - 2 hours. 7) Through multiple drawing passes, the bar with a diameter of 4mm-6mm is further drawn to a diameter of 1.5mm-2mm, wherein the deformation in each pass is controlled at 10%-20%; 8) Draw the bar from step 7) into a wire with a target diameter of 0.8mm~1.2mm; 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire. 10) After the wire processed in step 9) is annealed, it is air-cooled. The annealing temperature is 300℃-350℃, and then it is held at that temperature for 1-2 hours. 11) Use sandblasting to remove dirt and rust from the surface of the wire to achieve the set surface roughness; 12) Ultrasonic cleaning is used to further remove impurities from the surface of the wire. The cleaned wire is then immersed in a chromate passivation solution for passivation treatment, and then dried.

10. A laser coaxial wire feeding additive manufacturing method for forming highly reflective materials according to claim 1, characterized in that, The method for manufacturing the filament is as follows: 1) Determine that the mass fraction of Cu in the copper alloy wire is greater than 99.9%; 2) Place the high-purity copper ingot in an induction furnace and control the temperature at 1100℃-1200℃. Add an appropriate amount of deoxidizer during the smelting process to reduce the oxygen content in the melt. Continuously introduce inert gas during the smelting process. The deoxidizer is phosphorus copper, and the mass fraction of phosphorus in the phosphorus copper is 0.03%-0.06%. 3) Pour the molten copper liquid into a water-cooled mold for continuous casting to form a copper ingot with a diameter of 100mm-200mm. Then, perform homogenization heat treatment on the copper ingot to eliminate compositional segregation and internal stress. The homogenization heat treatment temperature is 800℃-850℃ and the holding time is 6 hours-8 hours. 4) Preheat the copper ingot to 700℃-800℃ to soften it, and then extrude it into bars with a diameter of 8mm-12mm using an extrusion press. The extrusion ratio is controlled between 10:1 and 20:

1. 5) Clean the surface of the bar after extrusion in step 4) to remove the oxide layer and defects, then rinse it with clean water and dry it. The surface cleaning is pickling or mechanical polishing. 6) Through multiple drawing passes, the bar is gradually drawn from 8mm-12mm to 4mm-6mm. After every 3-5 drawing passes, intermediate annealing is performed at a temperature of 500℃-600℃ and a holding time of 1-2 hours. 7) Through multiple drawing passes, the 4mm-6mm bar is further drawn to 1.5mm-2mm. As the diameter of the bar decreases, the drawing speed gradually decreases, and the deformation in each pass is controlled at 10%-20%. 8) The bar from step 7) is drawn into a wire with a target diameter of 0.8 mm to 1.2 mm. During this process, the drawing speed is further reduced compared to the drawing speed in step 7). 9) N grooves are machined on the side of the wire, the length direction of each groove is consistent with the length direction of the wire, and these grooves are evenly arranged around the center line of the wire. 10) After annealing the wire processed in step 9), air cool it. The annealing temperature is 450℃-550℃ and the holding time is 1 hour-1.5 hours. 11) Use sandblasting to remove dirt and rust from the surface of the wire and create a set roughness on the surface of the wire; 12) Use a 5%-10% sulfuric acid solution to pickle the surface of the silk material to further remove impurities. After rinsing the surface of the silk material with clean water until it is neutral, dry it and then coat the dried silk material with an anti-oxidation grease.

Images