A method of making an aluminum alloy foamed welding wire

Abstract

The application provides a preparation method of aluminum alloy foaming welding wire and belongs to the technical field of aluminum alloy welding wire production. After smelting an aluminum alloy base, a foaming stabilizer and a high-temperature foaming body are added step by step, and the foaming welding wire is prepared through processes such as stirring and mixing, rapid cooling of a casting mold, homogenization annealing, multi-pass extrusion and drawing. Through the technical scheme, the application can realize rapid filling and connection of the welding seam area after aluminum alloy material welding, and the welding seam filling area presents a typical porous morphology. The application realizes direct welding of light porous aluminum alloy material, avoids solidification of the welding seam area, is helpful to lightweight design, realizes welding foaming filling of a cavity of a metal component, can greatly improve cavity filling efficiency due to molten pool foaming, and endows the formed metal component with functions such as damping and vibration reduction. The application can be used as additive manufacturing welding wire and can directly perform additive preparation forming of porous aluminum alloy material.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of aluminum alloy welding, in particular, and particularly relates to a preparation method of aluminum alloy foaming welding wire. BACKGROUND

[0002] With the high-quality development of aerospace, rail transportation, new energy vehicles and other fields, aluminum alloy has become the preferred material in modern industrial fields due to its excellent specific strength, corrosion resistance and easy processing. As the core process of aluminum alloy part forming, the quality of welding directly affects the service performance and safety reliability of the product. Because of its economy and effectiveness, fusion welding is currently the main process for aluminum alloy welding. It can use heat sources such as arc, laser and electron beam to melt metal materials such as welding rod or welding wire to fill the weld and realize metallurgical bonding of aluminum alloy.

[0003] The indispensable material for aluminum alloy fusion welding is welding wire. However, due to the constraints of welding process technology and conditions, there are several problems in the traditional welding process that need to be solved: first, traditional welding wire needs multiple passes of repeated welding to fill the wide weld, resulting in low welding efficiency, large structural deformation, and large tendency of parent material organization grain coarsening; second, the weld formed by traditional welding wire is a solid weld with a density close to that of aluminum alloy, which is not conducive to the lightweight design of parts under certain working conditions, especially the connection of aluminum alloy plates or structures with functional special designs such as dot matrix structure or porous features; third, traditional welding wire can only achieve lightweight design and functional regulation of part structure by optimizing and adjusting the structure when used for arc additive manufacturing, and cannot directly utilize the properties of welding wire metal to achieve weld damping, sound insulation, electromagnetic shielding and other functional characteristics.

[0004] Therefore, it is urgent to develop a special aluminum alloy foaming welding wire that can realize foaming filling of welding wire during fusion welding and effectively solve the welding problem of lightweight dot matrix structure or porous feature aluminum alloy structural parts. The newly developed aluminum alloy foaming welding wire must meet the conditions of low price and large-scale industrial production. SUMMARY

[0005] In order to make up for the shortcomings of the prior art, the present application provides a preparation method of aluminum alloy foaming welding wire.

[0006] The present application is realized by the following technical scheme: a preparation method of aluminum alloy foaming welding wire, comprising the following steps:

[0007] Step (1) aluminum liquid smelting: add aluminum alloy base with preset chemical composition into a smelting furnace, heat and melt, and after all the furnace charges are melted, stir and remove slag;

[0008] Step (2) adding foaming stabilizer: transfer the melted aluminum alloy to the tundish, control the aluminum alloy melt temperature at 1.1 ~ 1.2 T 熔 , add foaming stabilizer to the aluminum alloy melt, and perform first stirring and mixing, the stirring and mixing time is 3 ~ 10 min; 熔 T is the melting point temperature of the aluminum alloy matrix;

[0009] Step (3) adding high-temperature foaming body: control the aluminum alloy melt temperature at T 熔 ~ 1.1 T 熔 , add high-temperature foaming body to the aluminum alloy melt, and perform second stirring and mixing, the stirring and mixing time is 0.5 ~ 4 min;

[0010] Step (4) rapid cooling: after the second stirring and mixing is completed, pour the aluminum alloy melt in the tundish into a metal mold, and cool the mold by cooling water to form a welding wire rod-shaped blank;

[0011] Step (5) homogenization annealing: heat the welding wire rod-shaped blank to 0.65~0.75 T 熔 , perform homogenization annealing, and the holding time is 2 ~ 10 h;

[0012] Step (6) blank extrusion: the welding wire rod-shaped blank after homogenization annealing is extruded through multiple passes to obtain a welding wire coil blank with a diameter of φ5~8 mm;

[0013] Step (7) first annealing: the welding wire coil blank obtained by extrusion is subjected to first heating annealing, and the annealing temperature is 0.75 ~ 0.85 T 熔 ;

[0014] Step (8) wire drawing: the welding wire coil blank after the first annealing is continuously drawn by using a wire drawing machine to obtain a welding wire line blank with a diameter of φ3 ~ 4 mm;

[0015] Step (9) second annealing: the welding wire line blank is subjected to second heating annealing, and the annealing temperature is 0.72 ~ 0.82 T 熔 ;

[0016] Step (10) finished product drawing: the welding wire line blank after the second annealing is subjected to finished product drawing to obtain aluminum alloy foaming welding wire products with a diameter of φ1.2, 1.6, 2.0, 3.2, 4.0 mm;

[0017] Step (11) cleaning and drying: the aluminum alloy foaming welding wire products are subjected to ultrasonic cleaning and hot air drying;

[0018] Step (12) coil packaging: the aluminum alloy foaming welding wire products after drying are continuously coiled and vacuum packaged.

[0019] As a preferred solution, the aluminum alloy base material in step 1 is an Al-Cu aluminum alloy, an Al-Mg aluminum alloy, an Al-Si aluminum alloy, an Al-Mg-Si aluminum alloy, or an Al-Zn-Mg-Cu aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foaming welding wire is not more than 20%.

[0020] As a preferred solution, the foaming stabilizer in step 2 includes two types of substances: the first type of substance is one or any combination of Ca and Mg metals, and the addition amount is 0.1-4.0wt.%; the second type of substance is one or any combination of Al2O3, ZrO2, SiC, TiC, and B4C particles with high melting points, and the particle size is 300-1000 mesh, and the addition amount is 0.5-3.0wt.%.

[0021] As a preferred solution, the stirring method is one or any combination of mechanical stirring, ultrasonic stirring, and electromagnetic stirring.

[0022] As a preferred solution, the addition amount of the high-temperature foaming body is 0.5-4wt.%, and the high-temperature foaming body is composed of two types of substances, i.e., a foaming agent and carrier particles, which are mixed by a ball milling process, the ball-to-material ratio is 3:1-10:1, the ball milling speed is 200-1000r / min, and the ball milling time is 2-12h.

[0023] Further, the foaming agent is a carbonate that releases CO2 by thermal decomposition, such as CaCO3, MgCO3, and CaMg(CO3)2, and a metal hydride that releases H2 by thermal decomposition, such as TiH2, MgH2, and CaH2, and the particle size of the foaming agent is 100-500mesh; the carrier particles are one or any combination of Al, Cu, Mg, and alloy particles that can be plastically deformed, and the particle size of the carrier particles is 80-400mesh.

[0024] As a preferred solution, the metal casting mold in step 4 has a cavity with an inner diameter of φ100-200mm and an inner height of 300-500mm, and a cooling water channel with an inner diameter of φ8-15mm is uniformly distributed in the cavity wall of the metal casting mold, the inlet temperature of the cooling water is 5-20℃, and the inlet pressure is 0.3-0.8MPa.

[0025] As a preferred solution, the extrusion ratio of each pass in the multi-pass extrusion in step 6 is 8%-16%, and the extrusion temperature of the welding wire rod blank is 0.67-0.77T 熔 .

[0026] As a preferred solution, one or any combination of solid lubricants of calcium stearate, barium stearate, zinc stearate, aluminum stearate, sodium stearate is used in step 8 for drawing into a wire.

[0027] As a preferred solution, the ultrasonic cleaning liquid temperature in step 11 is 45-60 DEG C, the hot air temperature for hot air drying is 70-80 DEG C, and the drying air speed is 0.5-3 m / s.

[0028] Compared with the existing aluminum alloy welding wire, the present application can realize rapid filling and connection of the weld area after welding of the aluminum alloy material, and the weld filling area presents a typical porous morphology.

[0029] Compared with the existing aluminum alloy welding wire, the present application can realize direct welding of lightweight porous aluminum alloy material, avoiding solidification of the weld area, and helping lightweight design.

[0030] The present application can realize welding foaming filling of the cavity of the metal member, and can greatly improve the cavity filling efficiency due to the molten pool foaming, and impart the formed metal member with damping and vibration reduction functions.

[0031] The present application can be used as an additive manufacturing welding wire, and can directly perform additive manufacturing forming of the porous aluminum alloy material.

[0032] Additional aspects and advantages of the present application will become apparent from the following description with reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0033] The above and / or additional aspects and advantages of the present application will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings in which:

[0034] Fig. 1 The present application is a preparation process flow chart;

[0035] Fig. 2 The present application is a cross-sectional schematic diagram of the aluminum alloy foaming welding wire;

[0036] Fig. 3 The present application is a schematic diagram of the weld filling of the aluminum alloy foaming welding wire. DETAILED DESCRIPTION

[0037] In order to more clearly understand the above-mentioned purposes, features and advantages of the present application, the present application will be further described in detail below in conjunction with the drawings and specific embodiments. It should be noted that the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

[0038] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. However, it will be apparent to one skilled in the art that the present application can be practiced without the specific details set forth in this description. In other instances, well-known methods have not been described in detail in order to avoid unnecessarily obscuring the present application.

[0039] The present application is described below in conjunction with Figs. 1-3 The aluminum alloy foaming welding wire preparation method of the embodiment of the present application is described in detail.

[0040] As Fig. 1 shown, the present application proposes an aluminum alloy foaming welding wire preparation method, comprising the following steps:

[0041] Embodiment 1

[0042] An aluminum alloy foaming welding wire preparation method, comprising the following steps:

[0043] Step (1) aluminum liquid smelting: add aluminum alloy matrix with preset chemical composition into a smelting furnace, heat and melt, after all the furnace charges are melted, stir and remove slag; the aluminum alloy matrix is Al-Cu series aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foaming welding wire is 10%.

[0044] Step (2) adding foaming stabilizer: transfer the melted aluminum alloy to a tundish, control the aluminum alloy melt temperature at 1.1 T 熔 , add the foaming stabilizer to the aluminum alloy melt, and perform the first stirring and mixing, the stirring and mixing time is 3 min; T 熔 is the melting point temperature of the aluminum alloy matrix; the foaming stabilizer includes two types of substances: the first type of substance is Ca metal element, the addition amount is 0.1 wt.%; the second type of substance is Al2O3 particle additive, the particle size is 350 mesh, and the addition amount is 0.8 wt.%.

[0045] Step (3) adding high-temperature foaming body: controlling the aluminum alloy melt temperature to T 熔 , adding the high-temperature foaming body to the aluminum alloy melt, and performing the second stirring and mixing, the stirring and mixing time is 1 min; the addition amount of the high-temperature foaming body is 0.5 wt.%, the high-temperature foaming body is composed of two types of substances, foaming agent and carrier particles, the foaming agent and the carrier particles are mixed by a ball milling process, the ball-to-material ratio is 3:1, the ball milling speed is 500 r / min, and the ball milling time is 2 h. The foaming agent refers to a single foaming agent or any combination of several foaming agents that can produce gas by thermal decomposition in a high-temperature environment, the foaming agent is CaCO3 and TiH2, and the foaming agent particle size is 100 mesh; the carrier particles are any combination of Al and Cu that can be plastically deformed, and the carrier particle size is 80 mesh.

[0046] Step (4) rapid cooling: after the second stirring mixing is completed, the aluminum alloy melt in the tundish is poured into a metal mold, and the mold is cooled by cooling water to form a welding wire rod-shaped blank; the metal mold has a cavity with an inner diameter of φ100 mm and an inner height of 300 mm, cooling water channels with an inner diameter of φ8 mm are uniformly distributed in the cavity wall of the metal mold, the cooling water inlet temperature is 10°C, and the inlet pressure is 0.3 MPa.

[0047] Step (5) homogenization annealing: the welding wire rod-shaped blank is heated to 0.65T 熔 The homogenization annealing is performed for 2h;

[0048] Step (6) blank extrusion: the welding wire rod-shaped blank after homogenization annealing is obtained by multi-pass extrusion to obtain a welding wire coil blank with a diameter of φ5mm; the extrusion ratio of each pass in the multi-pass extrusion is 8%, and the extrusion temperature of the welding wire rod-shaped blank is 0.67T 熔 .

[0049] Step (7) first annealing: the welding wire coil blank obtained by extrusion is subjected to first heating annealing, and the annealing temperature is 0.75 T 熔 ;

[0050] Step (8) wire drawing: the welding wire coil blank after the first annealing is continuously drawn by using a wire drawing machine to obtain a welding wire line blank with a diameter of φ3 mm; calcium stearate solid lubricant is used for wire drawing.

[0051] Step (9) second annealing: the welding wire line blank is subjected to second heating annealing, and the annealing temperature is 0.72T 熔 ;

[0052] Step (10) finished product drawing: the welding wire line blank after the second annealing is subjected to finished product drawing to obtain an aluminum alloy foaming welding wire product with a diameter of φ1.2 mm;

[0053] Step (11) cleaning and drying: the aluminum alloy foaming welding wire product is subjected to ultrasonic cleaning and hot air drying; the ultrasonic cleaning liquid temperature is 45°C, the hot air drying temperature is 70°C, and the drying air speed is 0.5 m / s.

[0054] Step (12) wire coiling and packaging: the aluminum alloy foaming welding wire product after drying is continuously coiled and vacuum packaged.

[0055] Example 2

[0056] A method for preparing an aluminum alloy foaming welding wire, comprising the following steps:

[0057] Step (1) aluminum liquid smelting: the aluminum alloy base with preset chemical composition is added into a smelting furnace, heated and melted, after all the furnace charges are melted, stirring and slag cleaning are performed; the aluminum alloy base is an Al-Mg series aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foaming welding wire is 12%.

[0058] Step (2) adding a foaming stabilizer: the melted aluminum alloy is transferred to a tundish, and the temperature of the aluminum alloy melt is controlled at 1.1 T 熔 The foaming stabilizer is added to the aluminum alloy melt, and first stirring and mixing is performed, and the stirring and mixing time is 5 min; T 熔 is the melting point temperature of the aluminum alloy base; the foaming stabilizer includes two types of substances: the first type of substance is Ca metal element, and the addition amount is 0.5 wt.%; the second type of substance is a ZrO2 particle additive, the particle size is 300 mesh, and the addition amount is 0.5 wt.%.

[0059] Step (3) adding a high-temperature foaming body: the temperature of the aluminum alloy melt is controlled at T 熔 The high-temperature foaming body is added to the aluminum alloy melt, and second stirring and mixing is performed, and the stirring and mixing time is 2 min; the addition amount of the high-temperature foaming body is 1.0 wt.%, the high-temperature foaming body is composed of two types of substances, a foaming agent and a carrier particle, the foaming agent and the carrier particle are mixed by a ball milling process, the ball-to-material ratio is 5:1, the ball milling speed is 200 r / min, and the ball milling time is 5 h. The foaming agent refers to a single foaming agent or any combination of several foaming agents that can produce gas under high temperature environment, the foaming agent is MgCO3 carbonates that release CO2 by thermal decomposition and metal hydride MgH2 that releases H2 by thermal decomposition, and the particle size of the foaming agent is 200 mesh; the carrier particle is any combination of Al and Cu that can be plastically deformed, and the particle size of the carrier particle is 100 mesh.

[0060] Step (4) rapid cooling: after the second stirring and mixing is completed, the aluminum alloy melt in the tundish is poured into a metal mold, and the mold is cooled by cooling water to form a welding wire rod-shaped blank; the metal mold has a cavity with an inner diameter of φ100 mm and an inner height of 300 mm, the cavity wall of the metal mold is uniformly distributed with cooling water channels with an inner diameter of φ10 mm, the cooling water inlet temperature is 10℃, and the inlet pressure is between 0.5 MPa.

[0061] Step (5) homogenization annealing: the welding wire rod-shaped blank is heated to 0.65T 熔 for homogenization annealing, and the holding time is 3 h;

[0062] Step (6) blank extrusion: the welding wire rod-shaped blank after homogenization annealing is extruded through multiple passes to obtain a welding wire coil blank with a diameter of φ6 mm; the extrusion ratio of each pass in the multiple passes is 10%, and the extrusion temperature of the welding wire rod-shaped blank is 0.67T 熔 .

[0063] Step (7) once annealing: the extruded welding wire rod blank is subjected to first heating annealing, and the annealing temperature is 0.80 T 熔 ;

[0064] Step (8) wire drawing: the welding wire rod blank subjected to the first annealing is continuously drawn by using a wire drawing machine to obtain a welding wire wire blank with a diameter of φ3 mm; calcium stearate solid lubricant is used for wire drawing.

[0065] Step (9) secondary annealing: the welding wire wire blank is subjected to second heating annealing, and the annealing temperature is 0.75 T 熔 ;

[0066] Step (10) product drawing: the welding wire wire blank subjected to the second annealing is subjected to product drawing to obtain an aluminum alloy foaming welding wire product with a diameter of φ1.6 mm;

[0067] Step (11) cleaning and drying: the aluminum alloy foaming welding wire product is subjected to ultrasonic cleaning and hot air drying; the ultrasonic cleaning liquid temperature is 50°C, the hot air drying hot air temperature is 70°C, and the drying air speed is 0.5 m / s.

[0068] Step (12) wire coiling and packaging: the aluminum alloy foaming welding wire product after drying is continuously coiled and vacuum packaged.

[0069] Example 3

[0070] A method for preparing an aluminum alloy foaming welding wire, comprising the following steps:

[0071] Step (1) aluminum liquid smelting: an aluminum alloy base body with a preset chemical composition is added to a smelting furnace for heating and melting, after all the furnace charges are melted, stirring and slag removal are performed; the aluminum alloy base body is an Al-Si series aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foaming welding wire is 10%.

[0072] Step (2) adding foaming stabilizer: the melted aluminum alloy is transferred to a tundish, the aluminum alloy melt temperature is controlled at 1.1 T 熔 , a foaming stabilizer is added to the aluminum alloy melt, and first stirring and mixing is performed, and the stirring and mixing time is 6 min; T 熔 is the melting point temperature of the aluminum alloy base body; the foaming stabilizer includes two types of substances: the first type of substance is Mg metal element, and the addition amount is 1.0 wt.%; the second type of substance is an Al2O3 particle additive with a particle size of 200 mesh, and the addition amount is 1.0 wt.%.

[0073] Step (3) adding high-temperature foaming body: the aluminum alloy melt temperature is controlled at 1.1 T 熔The high-temperature foaming body is added to the aluminum alloy melt, and second stirring and mixing is performed for 0.5 min; the high-temperature foaming body is added in an amount of 0.5 wt.%, and the high-temperature foaming body is composed of two types of substances, i.e., a foaming agent and carrier particles, which are mixed by a ball milling process, with a ball-to-material ratio of 4:1, a ball milling speed of 500 r / min, and a ball milling time of 5 h. The foaming agent refers to a single foaming agent or any combination of several foaming agents that can generate gas by thermal decomposition in a high-temperature environment, and the foaming agent is a carbonate CaMg(CO3)2 that releases CO2 by thermal decomposition and a metal hydride TiH2 that releases H2 by thermal decomposition, with a particle size of 400 mesh; the carrier particles are any combination of Al and Mg that can be plastically deformed, with a particle size of 300 mesh.

[0074] Step (4) rapid cooling: after the second stirring and mixing is completed, the aluminum alloy melt in the tundish is poured into a metal mold, and cooling water is passed through the mold to cool the mold, thereby forming a welding wire rod-shaped blank; the metal mold has a cavity with an inner diameter of φ200 mm and an inner height of 500 mm, and cooling water channels with an inner diameter of φ15 mm are uniformly distributed in the cavity wall of the metal mold; the inlet temperature of the cooling water is 20°C, and the inlet pressure is 0.8 MPa.

[0075] Step (5) homogenization annealing: the welding wire rod-shaped blank is heated to 0.75T 熔 , and homogenization annealing is performed for 5 h;

[0076] Step (6) blank extrusion: the welding wire rod-shaped blank after homogenization annealing is subjected to multi-pass extrusion to obtain a welding wire coil blank with a diameter of φ8 mm; the extrusion ratio of each pass in the multi-pass extrusion is 10%, and the extrusion temperature of the welding wire rod-shaped blank is 0.77T 熔 .

[0077] Step (7) first annealing: the welding wire coil blank obtained by extrusion is subjected to first heating annealing at an annealing temperature of 0.85 T 熔 ;

[0078] Step (8) wire drawing: the welding wire coil blank after the first annealing is continuously drawn by using a wire drawing machine to obtain a welding wire line blank with a diameter of φ4 mm; calcium stearate solid lubricant is used for wire drawing.

[0079] Step (9) second annealing: the welding wire line blank is subjected to second heating annealing at an annealing temperature of 0.8 T 熔 ;

[0080] Step (10) finished product drawing: the welding wire line blank after the second annealing is subjected to finished product drawing to obtain an aluminum alloy foaming welding wire product with a diameter of φ2.0 mm;

[0081] Step (11) cleaning and drying: the aluminum alloy foaming welding wire product is ultrasonic cleaned and hot air dried; the ultrasonic cleaning liquid temperature is 60°C, the hot air drying hot air temperature is 75°C, and the drying air speed is 3 m / s.

[0082] Step (12) disc winding: the dried aluminum alloy foaming welding wire product is continuously wound and vacuum packaged.

[0083] Example 4

[0084] An aluminum alloy foaming welding wire preparation method comprises the following steps:

[0085] Step (1) aluminum liquid smelting: a preset chemical composition aluminum alloy base is added to a smelting furnace, heated and melted, and after all the furnace charges are melted, stirring and slag removal are performed; the aluminum alloy base is an Al-Mg-Si system aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foaming welding wire is 15%.

[0086] Step (2) adding foaming stabilizer: the melted aluminum alloy is transferred to a tundish, and the aluminum alloy melt temperature is controlled at 1.2 T 熔 Foaming stabilizer is added to the aluminum alloy melt, and first stirring and mixing is performed, with a stirring and mixing time of 10 min; T 熔 is the melting point temperature of the aluminum alloy base; the foaming stabilizer comprises two types of substances: the first type of substance is Mg metal element, with an addition amount of 3.0 wt.%; the second type of substance is TiC particle additive, with a particle size of 500 mesh and an addition amount of 3.0 wt.%.

[0087] Step (3) adding high-temperature foaming body: the aluminum alloy melt temperature is controlled at 1.1 T 熔 The high-temperature foaming body is added to the aluminum alloy melt, and second stirring and mixing is performed, with a stirring and mixing time of 2.0 min; the high-temperature foaming body addition amount is 2.0 wt.%, the high-temperature foaming body is composed of two types of substances, foaming agent and carrier particles, the foaming agent and carrier particles are mixed by a ball milling process, the ball-to-material ratio is 8:1, the ball milling speed is 1000 r / min, and the ball milling time is 10 h. The foaming agent refers to a single foaming agent or any combination of several foaming agents that can thermally decompose to produce gas in a high-temperature environment, the foaming agent is CaMg(CO3)2 carbonates that thermally decompose to release CO2 and metal hydride CaH2 that thermally decomposes to release H2, and the foaming agent particle size is 100 mesh; the carrier particles are any combination of Al and Mg that can be plastically deformed, and the carrier particle size is 400 mesh.

[0088] Step (4) rapid cooling: after the second stirring mixing is completed, the aluminum alloy melt in the tundish is poured into a metal mold, and the mold is cooled by cooling water to form a welding wire rod-shaped blank; the metal mold has a cavity with an inner diameter of φ100 mm and an inner height of 300 mm, cooling water channels with an inner diameter of φ10 mm are uniformly distributed in the cavity wall of the metal mold, the cooling water inlet temperature is 10°C, and the inlet pressure is 0.5 MPa.

[0089] Step (5) homogenization annealing: the welding wire rod-shaped blank is heated to 0.7T 熔 The homogenization annealing is performed for 10 h;

[0090] Step (6) blank extrusion: the welding wire rod-shaped blank after homogenization annealing is obtained by multi-pass extrusion to obtain a welding wire coil blank with a diameter of φ7 mm; the extrusion ratio of each pass in the multi-pass extrusion is 16%, and the extrusion temperature of the welding wire rod-shaped blank is 0.67T 熔 .

[0091] Step (7) first annealing: the welding wire coil blank obtained by extrusion is subjected to first heating annealing, and the annealing temperature is 0.80 T 熔 ;

[0092] Step (8) wire drawing: the welding wire coil blank after the first annealing is continuously drawn by using a wire drawing machine to obtain a welding wire line blank with a diameter of φ4 mm; calcium stearate solid lubricant is used for wire drawing.

[0093] Step (9) second annealing: the welding wire line blank is subjected to second heating annealing, and the annealing temperature is 0.8 T 熔 ;

[0094] Step (10) finished product drawing: the welding wire line blank after the second annealing is subjected to finished product drawing to obtain an aluminum alloy foaming welding wire product with a diameter of φ3.2 mm;

[0095] Step (11) cleaning and drying: the aluminum alloy foaming welding wire product is subjected to ultrasonic cleaning and hot air drying; the ultrasonic cleaning liquid temperature is 55°C, the hot air drying temperature is 80°C, and the drying air speed is 1 m / s.

[0096] Step (12) wire coiling and packaging: the aluminum alloy foaming welding wire product after drying is continuously coiled and vacuum packaged.

[0097] Example 5

[0098] A method for preparing an aluminum alloy foaming welding wire, comprising the following steps:

[0099] Step (1) aluminum liquid smelting: the aluminum alloy base with preset chemical composition is added into a smelting furnace, heated and melted, after all the furnace charges are melted, stirring and slag cleaning are performed; the aluminum alloy base is an Al-Zn-Mg-Cu aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foaming welding wire is 10%.

[0100] Step (2) adding foaming stabilizer: the melted aluminum alloy is transferred to a tundish, the temperature of the aluminum alloy melt is controlled at 1.2 T 熔 , the foaming stabilizer is added into the aluminum alloy melt, and first stirring and mixing is performed, the stirring and mixing time is 8 min; T 熔 is the melting point temperature of the aluminum alloy base; the foaming stabilizer includes two types of substances: the first type of substance is Ca metal element, the addition amount is 4.0 wt.%; the second type of substance is B4C particle additive, the particle size is 1000 mesh, and the addition amount is 2.0 wt.%.

[0101] Step (3) adding high-temperature foaming body: the temperature of the aluminum alloy melt is controlled at T 熔 , the high-temperature foaming body is added into the aluminum alloy melt, and second stirring and mixing is performed, the stirring and mixing time is 4.0 min; the addition amount of the high-temperature foaming body is 4.0 wt.%, the high-temperature foaming body is composed of two types of substances, foaming agent and carrier particles, the foaming agent and the carrier particles are mixed by a ball milling process, the ball-to-material ratio is 10:1, the ball milling speed is 800 r / min, and the ball milling time is 8 h. The foaming agent refers to a single foaming agent or any combination of several foaming agents that can produce gas under high temperature environment, the foaming agent is CaMg(CO3)2 carbonates that release CO2 by thermal decomposition and CaH2 metal hydride that releases H2 by thermal decomposition, the particle size of the foaming agent is 500 mesh; the carrier particles are any combination of Al and Cu that can be plastically deformed, and the particle size of the carrier particles is 400 mesh.

[0102] Step (4) rapid cooling: after the second stirring and mixing is completed, the aluminum alloy melt in the tundish is poured into a metal mold, and the mold is cooled by cooling water to form a welding wire rod-shaped blank; the metal mold has a cavity with an inner diameter of φ100 mm and an inner height of 500 mm, cooling water channels with an inner diameter of φ10 mm are uniformly distributed in the cavity wall of the metal mold, the inlet temperature of the cooling water is 10℃, and the inlet pressure is between 0.5 MPa.

[0103] Step (5) homogenization annealing: the welding wire rod-shaped blank is heated to 0.7T 熔 for homogenization annealing, and the holding time is 10 h;

[0104] Step (6) blank extrusion: the welding wire rod-shaped blank after homogenization annealing is extruded through multiple passes to obtain a welding wire coil blank with a diameter of φ7 mm; the extrusion ratio of each pass in the multiple passes is 16%, and the extrusion temperature of the welding wire rod-shaped blank is 0.77T熔 .

[0105] Step (7) first annealing: the extruded welding wire rod blank is subjected to first heating annealing, and the annealing temperature is 0.80 T 熔 ;

[0106] Step (8) wire drawing: the welding wire rod blank subjected to the first annealing is continuously drawn by using a wire drawing machine to obtain a welding wire blank with a diameter of φ4 mm; the calcium stearate solid lubricant is used for wire drawing.

[0107] Step (9) second annealing: the welding wire blank is subjected to second heating annealing, and the annealing temperature is 0.8 T 熔 ;

[0108] Step (10) product drawing: the welding wire blank subjected to the second annealing is subjected to product drawing to obtain an aluminum alloy foaming welding wire product with a diameter of φ4.0 mm;

[0109] Step (11) cleaning and drying: the aluminum alloy foaming welding wire product is subjected to ultrasonic cleaning and hot air drying; the ultrasonic cleaning liquid temperature is 50℃, the hot air drying hot air temperature is 80℃, and the drying air speed is 1 m / s.

[0110] Step (12) wire coiling and packaging: the aluminum alloy foaming welding wire product after drying is continuously coiled and vacuum packaged.

[0111] Results and discussion

[0112] Table 1 aluminum alloy foaming welding wires prepared by different examples

[0113] Table 2 aluminum alloy soldering experiments using different aluminum alloy foaming welding wires prepared by examples

[0114]

[0115] Table 2 shows that different welding wires are prepared into different diameters including 1.2 mm, 1.6 mm, 2.0 mm, 3.2 mm, 4.0 mm, compared with the existing aluminum alloy welding wire, the aluminum alloy welding seam area can be quickly filled and connected by using the present application, and the welding seam filling area presents a typical porous morphology, the average size of the welding seam area pores (0.8~2.5 mm) and the porosity (43%~73%) are affected by the high-temperature foaming body in the aluminum alloy foaming welding wire and the welding process parameters. The porous welding seam area can make the aluminum alloy foaming welding wire directly applied to the welding forming of the porous aluminum alloy material, avoiding the solidification of the welding seam after the traditional aluminum alloy welding wire forming. The aluminum alloy surface is "surfacing" by using the embodiment, a light foaming layer with good combination with the aluminum alloy substrate and a porous morphology can be obtained, the bearing strength is 6.5~20.5 MPa, and the porous surface structure can endow the metal member with functional characteristics such as damping and vibration reduction. The aluminum alloy foaming welding wire of the embodiment can be used as an additive manufacturing welding wire, realizing the additive manufacturing forming of the porous aluminum alloy material and improving the production efficiency.

[0116] In the description of the present application, the term "a plurality of" refers to two or more, unless otherwise explicitly limited, and the terms "upper", "lower", and the like indicate the orientation or positional relationship shown in the drawings based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application; the terms "connection", "installation", "fixation" and the like should be understood in a broad sense, for example, "connection" can be fixed connection, can also be detachable connection, or integral connection; can be directly connected, or indirectly connected through an intermediate medium. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0117] In the description of the present application, the terms "one embodiment", "some embodiments", "a specific embodiment" and the like mean that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present description, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0118] The above is only the preferred embodiment of the present application and is not used to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A method for preparing aluminum alloy foamed welding wire, characterized in that... This includes the following steps: Step (1) Aluminum molten metal smelting: Add the aluminum alloy matrix with the preset chemical composition into the smelting furnace, heat and melt it. After all the furnace charge has melted, stir and remove the slag. Step (2) Adding foaming stabilizer: Transfer the molten aluminum alloy to the tundish and adjust the temperature of the molten aluminum alloy to 1.1 ~ 1.2 T. 熔 Add a foaming stabilizer to the molten aluminum alloy and perform a first stirring and mixing process for 3 to 10 minutes; T 熔 This refers to the melting point temperature of the aluminum alloy matrix. Step (3) Add high-temperature foaming material: Adjust the temperature of the aluminum alloy melt to T 熔 ~ 1.1 T 熔 The high-temperature foam is added to the aluminum alloy melt and then stirred and mixed for a second time for 0.5 to 4 minutes. Step (4) Rapid cooling: After the second stirring and mixing is completed, the aluminum alloy melt in the tundish is poured into the metal mold, and cooling water is passed through to cool the mold to form a welding wire rod billet; Step (5) Homogenization annealing: Heat the welding wire rod blank to 0.65~0.75 T. 熔 Perform homogenization annealing, holding time 2 ~ 10 h; Step (6) Blank extrusion: The homogenized and annealed welding wire rod blank is extruded through multiple passes to obtain welding wire wire rod blank with a diameter of φ5~8mm; Step (7) First annealing: The extruded welding wire rod blank is subjected to a first heating annealing at a temperature of 0.75 ~ 0.85 T. 熔 ; Step (8) Drawing into wire: The above-mentioned annealed welding wire rod blank is continuously drawn using a wire drawing machine to obtain a welding wire blank with a diameter of φ3 ~ 4 mm; Step (9) Secondary annealing: The welding wire blank is heated and annealed a second time at a temperature of 0.72 ~ 0.82 T. 熔 ; Step (10) Finished product drawing: The annealed welding wire blank is drawn into finished products to obtain aluminum alloy foamed welding wire finished products with diameters of φ1.2, 1.6, 2.0, 3.2 and 4.0 mm; Step (11) Cleaning and drying: The finished aluminum alloy foamed welding wire is ultrasonically cleaned and then dried with hot air. Step (12) Wire Coiling and Packaging: The dried aluminum alloy foamed welding wire is continuously coiled and vacuum-packed.

2. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... The aluminum alloy matrix in step (1) is one or any combination of Al-Cu aluminum alloy, Al-Mg aluminum alloy, Al-Si aluminum alloy, Al-Mg-Si aluminum alloy, and Al-Zn-Mg-Cu aluminum alloy, and the total mass fraction of alloying elements in the aluminum alloy foamed welding wire does not exceed 20%.

3. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... The foaming stabilizer in step (2) includes two types of substances: the first type is one or any combination of Ca and Mg metal elements, with an addition amount of 0.1 to 4.0 wt.%; the second type is one or any combination of Al2O3, ZrO2, SiC, TiC, and B4C particles with high melting points, with a particle size of 300 to 1000 mesh, and an addition amount of 0.5 to 3.0 wt.%.

4. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... The stirring method is one or any combination of mechanical stirring, ultrasonic stirring, and electromagnetic stirring.

5. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... The high-temperature foam is added at a rate of 0.5 to 4 wt.%, and the high-temperature foam is composed of two types of substances: foaming agent and carrier particles. The foaming agent and carrier particles are mixed by ball milling, with a ball-to-material ratio of 3:1 to 10:1, a ball milling speed of 200 to 1000 r / min, and a ball milling time of 2 to 12 h.

6. The method for preparing aluminum alloy foamed welding wire according to claim 5, characterized in that, The foaming agent is a carbonate of CaCO3, MgCO3, or CaMg(CO3)2 that releases CO2 upon thermal decomposition, and a metal hydride of TiH2, MgH2, or CaH2 that releases H2 upon thermal decomposition. The particle size of the foaming agent is 100-500 mesh. The carrier particles are one or any combination of plastically deformable Al, Cu, Mg, and their alloy particles. The particle size of the carrier particles is 80-400 mesh.

7. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... The metal mold in step (4) is a cavity with an inner diameter between φ100 and 200 mm and an inner height between 300 and 500 mm. Cooling water channels with an inner diameter of φ8 to 15 mm are evenly distributed inside the cavity wall of the metal mold. The inlet temperature of the cooling water is 5℃ to 20℃ and the inlet pressure is between 0.3 and 0.8 MPa.

8. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... In step (6), the extrusion ratio of each pass in the multi-pass extrusion is 8% to 16%, and the extrusion temperature of the welding wire rod billet is 0.67 to 0.77 T. 熔 .

9. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... In step (8), the solid lubricant used to draw the wire is one or any combination of calcium stearate, barium stearate, zinc stearate, aluminum stearate, and sodium stearate.

10. The method for preparing aluminum alloy foamed welding wire according to claim 1, characterized in that... The temperature of the ultrasonic cleaning liquid in step (11) is 45℃ ~ 60℃, the temperature of the hot air for drying is 70℃ ~ 80℃, and the drying air velocity is 0.5 ~ 3 m / s.

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