Liquid-solid composite manufacturing method for steel-aluminum dissimilar material with local semi-closed structure
By employing a liquid-solid composite manufacturing method, combined with additive and deformation processes, and using a multi-component gradient transition layer and multi-directional hot molding, the problem of difficult interface bonding between dissimilar steel and aluminum materials was solved, achieving efficient and high-quality composite manufacturing and improving the overall performance and interface bonding strength of the materials.
Patent Information
- Application Number
- CN202511126582.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-12
- Publication Date
- 2025-11-18
AI Technical Summary
When steel and aluminum are directly composited, the interface bonding is difficult, which easily leads to cracks and porosity defects, resulting in poor performance of composite materials. Existing welding, riveting and adhesive bonding methods are difficult to achieve efficient and high-quality metallurgical bonding.
A liquid-solid composite manufacturing method is adopted, which utilizes additive deposition and multi-directional hot molding in an inert atmosphere using additive and deformation devices. The microstructure and properties are optimized by cyclic plastic deformation technology, and the heating temperature is precisely controlled by pulse circuit to form a multi-component gradient transition layer and perform multi-directional hot molding, thereby achieving efficient composite of steel and aluminum dissimilar materials.
It improves the bonding strength and overall performance of dissimilar steel and aluminum materials, reduces interfacial stress concentration, enhances fatigue resistance and corrosion resistance, simplifies the process, and improves manufacturing quality and efficiency.
Smart Images
Figure CN120961850A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of steel-aluminum dissimilar material composite manufacturing, in particular to a steel-aluminum dissimilar material liquid-solid composite manufacturing method with a local semi-closed structure. BACKGROUND
[0002] Steel-aluminum dissimilar materials have become an ideal choice for realizing the combination of lightweight and high performance due to their unique performance advantages. However, due to the significant differences in physical and chemical properties between steel and aluminum, such as melting point, thermal expansion coefficient, and crystal structure, it is difficult to directly composite manufacture them, and cracks and pores are easily produced, which seriously affects the performance and reliability of the composite material. Therefore, how to realize efficient and high-quality composite manufacturing of steel-aluminum dissimilar materials has become a research hotspot and difficulty in the field of material science.
[0003] Traditional steel-aluminum dissimilar material composite manufacturing technologies, such as welding, riveting, and gluing, have achieved the connection of steel-aluminum materials to some extent, but all have obvious shortcomings. In the welding process, due to the large difference in thermal expansion coefficient between steel and aluminum, thermal stress and cracks are easily produced; riveting increases the weight and complexity of the structure, and the connection strength is limited; gluing can maintain the flatness of the interface, but the temperature resistance and durability are poor. More importantly, these traditional methods often fail to achieve good metallurgical bonding at the steel-aluminum interface, resulting in poor interface performance of the composite material, limiting its application range and performance improvement. Therefore, it is necessary to develop a new technology that can efficiently and high-quality realize the composite manufacturing of steel-aluminum dissimilar materials. SUMMARY
[0004] The present application aims to solve the problems in the background art and provides a steel-aluminum dissimilar material liquid-solid composite manufacturing method with a local semi-closed structure.
[0005] The present application adopts the following technical solutions.
[0006] A steel-aluminum dissimilar material liquid-solid composite manufacturing method with a local semi-closed structure adopts a liquid-solid composite manufacturing device, which includes an additive device and a deformation device; the lower molds of the additive device and the deformation device share a slidable sealing workbench under an inert atmosphere at different process periods.
[0007] Further, the upper die of the deformation device comprises an end punch and a core punch; the slidable sealing workbench comprises a seat plate, a cushion plate, a lower die, a limiting plate, an upper die, a pressing plate, a left die, a right die, a left punch and a right punch; the seat plate is fixed on the upper surface of the table plate of the slidable sealing workbench; the left punch passes through the limiting hole on the left side of the cushion plate horizontally and is fixed on the upper surface of the seat plate, and the right punch passes through the limiting hole on the right side of the cushion plate horizontally and is fixed on the upper surface of the seat plate; the lower die is installed on the upper surface of the cushion plate; the limiting plate is installed on the upper surface of the lower die; the left die and the right die are arranged in the region between the upper surface of the lower die and the limiting plate; the upper die is installed on the upper surfaces of the limiting plate, the left die and the right die; the pressing plate is installed on the upper surface of the upper die; the internal space of the slidable sealing workbench can be vacuumized to an absolute pressure of 0.02-0.04 MPa; the axial central region of the upper die and the cushion plate is provided with the positive and negative electrodes of the pulse circuit and the temperature sensor.
[0008] Further, the blank of the steel-aluminum dissimilar material is composed of a steel base and an aluminum additive; the additive comprises a transition layer at the steel-aluminum interface; the base cooperates with the middle region of the lower die; the additive cooperates with the middle region of the upper die; the left die and the right die cooperate with the necked part of the blank.
[0009] In the steel-aluminum dissimilar material liquid-solid composite manufacturing method, the steps comprise:
[0010] S100: placing the base in the lower die and moving the slidable sealing workbench to the additive work station; under the protection of inert gas, depositing the transition layer on the surface of the base layer by layer to the designed size through the additive tool system, and cleaning the flash and burrs of the obtained transition layer;
[0011] S200: moving away the additive tool system, moving the slidable sealing workbench to the deformation work station, and vacuumizing the inner cavity of the slidable sealing workbench to a vacuum state;
[0012] S300: starting the pulse circuit to heat the transition layer to a specified temperature, pouring molten aluminum on the surface of the transition layer, and forming the additive after cooling and solidification;
[0013] S400: applying a multi-directional hot die pressing load of 100-200 MPa to the blank by the end punch, the core punch, the left punch and the right punch;
[0014] S500: controlling the end punch and the core punch to load and displace along the axial direction to form an axially open cavity, controlling the left punch and the right punch to load and displace along the transverse direction to form a radially open cavity, and realizing the plastic deformation of the blank from the initial state to the intermediate state and then from the intermediate state to the target shape.
[0015] Preferably, the heating average current density of the temperature monitoring system is 15-25 A / mm 2, the power is 50-70kW, the heating is started when the temperature is lower than 450℃, the heating is stopped and the temperature warning is triggered when the temperature is higher than 500℃.
[0016] Preferably, in the process of layer-by-layer deposition of the transition layer on the substrate surface by laser additive method, the laser power is 1000-1600W, the scanning speed is 2-6mm / s, and the powder particle size is 60-120μm.
[0017] Preferably, the transition layer is a multi-component gradient material, which sequentially contains the following layers from the side close to the steel substrate to the side close to the additive body:
[0018] The first layer is an alloy layer with Fe as the main element;
[0019] The second layer is an alloy layer with the composition of Fe x -CoCrNiCu y , wherein the atomic ratio of Co, Cr and Ni is 1:1:1, x represents the ratio of the number of Fe atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 3, and y represents the ratio of the number of Cu atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 1.2;
[0020] The third layer is an alloy layer with the composition of CoCrNiCu y , wherein the atomic ratio of Co, Cr and Ni is 1:1:1, and y represents the ratio of the number of Cu atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 1.2;
[0021] The fourth layer is an alloy layer with the composition of CoCrNiCu y -AI Z , wherein the atomic ratio of Co, Cr and Ni is 1:1:1, y represents the ratio of the number of Cu atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 1.2, and Z represents the ratio of the number of Al atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 3;
[0022] The fifth layer is an alloy layer with Al as the main element.
[0023] Further, the top of the transition layer has a dovetail groove, and the bottom of the transition layer has a protruding part.
[0024] Further, during the process of applying multi-directional hot die pressing load to the blank, the core punch is controlled to impact vibration at a frequency of 180 times per second, and the vibration displacement is controlled to 2mm.
[0025] Further, the blank is deformed from the initial state to the intermediate state, and then from the intermediate state to the initial state, the number of cycles is 1-3 times, and the single deformation amount is between the dynamic recrystallization critical deformation amount and the steady state deformation amount. The speed of driving the metal volume transfer should meet the following conditions: Wherein, e is a natural constant, h0 is the height of the initial state blank, is the material strain rate, t is the cumulative time of the blank from the initial state to the intermediate state, the strain rate is between 0.01-1.
[0026] Beneficial effects: The application realizes efficient integration of additive and deformation processes, greatly simplifies the process flow, reduces equipment space occupation and operation complexity, ensures uniformity and density of the steel-aluminum interface transition layer during the manufacturing process, promotes element diffusion and organization densification, improves the bonding strength and overall performance of the composite material, realizes precise control of the heating temperature of the transition layer, avoids performance decline caused by overheating or insufficient heating, improves manufacturing quality and efficiency, and provides a new way for efficient and high-quality composite manufacturing of steel-aluminum dissimilar materials.
[0027] The application optimizes the organization performance of the steel-aluminum dissimilar material composite body through cyclic plastic deformation technology. During the manufacturing process, the end punch, core punch, left and right punches and the corresponding processes work together, so that the additive body undergoes cyclic plastic deformation, effectively eliminates internal stress, refines the grain structure, improves the comprehensive mechanical properties of the material, further enhances the bonding strength of the steel-aluminum interface, reduces the interface stress concentration, and improves the fatigue resistance and corrosion resistance of the composite material. BRIEF DESCRIPTION OF DRAWINGS
[0028] In order to more clearly illustrate the technical solutions of the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description. Obviously, the drawings in the following description are only some embodiments of the application, and those skilled in the art can obtain other drawings according to these drawings without creating any inventive labor.
[0029] Figure 1 It is a flowchart of the steel-aluminum dissimilar material liquid-solid composite manufacturing method with a local semi-closed structure in Example 1. In the figure, (a) part represents a schematic diagram of forming a transition layer, (b) part represents a schematic diagram of pouring a melt, (c) part represents a schematic diagram before applying multi-directional hot die pressing to the blank, (d) part represents a schematic diagram during the process of applying multi-directional hot die pressing to the blank, (e) part represents a schematic diagram of axial loading using an end punch and a core punch, and (f) part represents a schematic diagram of axial loading using a core punch.
[0030] Figure 2 It is a schematic diagram of the steel-aluminum dissimilar material and its transition layer in Example 1.
[0031] Figure 3 It is a schematic diagram of the steel-aluminum dissimilar material and its transition layer in Example 2.
[0032] In the diagram: 1. End punch; 2. Core punch; 3. Pressure plate; 4. Upper die; 5. Limiting plate; 6. Lower die; 7. Pad plate; 8. Seat plate; 9. Left die; 10. Right die; 11. Left punch; 11a. Left punch in closed state; 12. Right punch; 12a. Right punch in open state; 13. Sliding sealing worktable; 14. Blank; 14a. Matrix; 14b. Additive body; 15. Additive tooling system; 16. Axially open cavity; 17. Temperature sensor; 18. Transition layer; 19. Casting equipment. Detailed Implementation
[0033] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.
[0034] Example 1 first describes the specific structure and working principle of the liquid-solid composite manufacturing device used.
[0035] like Figure 1 As shown, the overall structure of the device is as follows: the liquid-solid composite manufacturing device mainly consists of two parts: an additive manufacturing device and a deformation device. The two share a sliding sealed worktable 13. This design realizes the integration of additive manufacturing and deformation processing, which greatly improves production efficiency and material composite quality.
[0036] The additive manufacturing apparatus includes an additive tooling system 15, which typically consists of a laser emitter, a powder conveying mechanism, and a three-dimensional motion control component. The power of the laser emitter can be adjusted within the range of 1000-1600W, and the energy input can be precisely controlled according to the characteristics of different materials. The powder conveying mechanism is responsible for uniformly conveying metal powder with a particle size of 60-120μm to the laser action area, providing raw materials for the additive manufacturing process.
[0037] The upper die of the deformation device consists of an end punch 1 and a core punch 2. The end punch 1 is mainly used to apply pressure to the blank 14 in the axial direction, while the core punch 2 can perform axial loading on the blank 14 inside the end punch 1. The cooperation of the end punch 1, the core punch 2 and the left and right punches can realize multi-directional molding, which promotes the densification of the material structure and the diffusion of elements.
[0038] The slidable sealing workbench 13: the seat plate 8 is fixed on the upper surface of the slidable sealing workbench 13, providing a stable support base for the whole workbench; the left male die 11 passes through the limiting hole on the left side of the base plate 7 horizontally and is fixed on the upper surface of the seat plate 8 through fasteners; the right male die 12 passes through the limiting hole on the right side of the base plate 7 horizontally and is fixed on the upper surface of the seat plate 8, which ensures the position accuracy and stability of the left and right male dies 12 during the working process; the lower female die 6 is installed on the upper surface of the base plate 7 and is used to bear the base body 14a; the limiting plate 5 is installed on the upper surface of the lower female die 6 and plays a limiting role on the left and right female dies 9 and 10; the left and right female dies 9 and 10 are arranged in the area between the upper surface of the lower female die 6 and the limiting plate 5 and cooperate with the necked part of the blank 14 to realize the forming control of the specific part of the blank 14; the upper female die 4 is installed on the upper surfaces of the limiting plate 5, the left and right female dies 9 and 10, further limiting the forming space of the blank 14; the pressing plate 3 is installed on the upper surface of the upper female die 4 and is used to fix the upper female die 4, ensuring the stability of the whole die structure; the internal space of the slidable sealing workbench 13 (i.e. the inner cavity of the slidable sealing workbench 13) is sealed through the sealing structure (such as a sealing ring) between the components, and the inner cavity of the slidable sealing workbench 13 can be pumped to an absolute pressure of 0.02-0.04 MPa, providing a low-oxygen or oxygen-free environment for the liquid-solid composite manufacturing process, effectively preventing material oxidation.
[0039] Heating and temperature monitoring system: the axial center area of the upper female die 4 and the base plate 7 is provided with positive and negative poles of the pulse circuit and a temperature sensor 17, which together constitute a heating and temperature monitoring system; when the temperature is lower than 450℃, the pulse circuit 16 is controlled to automatically start heating, the average current density of heating is 15-25 A / mm 2 , and the power is 50-70 kW; when the temperature is higher than 500℃, the pulse circuit 16 is controlled to stop heating and trigger a temperature warning, ensuring that the temperature of the transition layer is always controlled within a reasonable range, avoiding the influence of high or low temperature on material performance.
[0040] Working principle: when liquid-solid composite manufacturing is carried out, the slidable sealing workbench 13 is first moved to the additive position, the additive tool system 15 deposits the transition layer on the surface of the base body 14a layer by layer through the laser additive deposition process under the protection of inert gas; after the additive is completed, the workbench is moved to the deformation position, the end male die 1 and the core male die 2 form a closed space with the slidable sealing workbench 13 and are pumped to vacuum, the transition layer is heated through the heating system, the molten aluminum or aluminum alloy forms new materials, and the blank 14 is subjected to multi-directional hot die load through the male dies, realizing the composite and forming of the materials.
[0041] Example 2, a steel-aluminum dissimilar material liquid-solid composite manufacturing method, as shown in Figures 1 to 3 , the steps include.
[0042] Prepare the raw materials for the steel substrate 14a and additive body 14b; correctly install each component on the sliding sealing worktable 13 (such as the seat plate 8, pad plate 7, lower die 6, limiting plate 5, upper die 4, pressure plate 3, left die 9, right die 10, left punch 11, and right punch 12), and check the installation accuracy and sealing performance of each component. At the same time, debug the additive tooling system 15, heating and temperature monitoring system, pulse circuit 16, and temperature sensor 17 to ensure their normal operation; prepare inert gas (such as argon), check the vacuum system, and ensure that the internal space of the sliding sealing worktable 13 can be evacuated to an absolute pressure of 0.02-0.04 MPa;
[0043] Additive manufacturing stage (S100):
[0044] The steel substrate 14a is precisely placed in the middle area of the lower die 6 in the lower mold, ensuring a tight fit between the substrate 14a and the lower die 6 to guarantee the accuracy of subsequent additive manufacturing; the sliding sealed worktable 13 is controlled to move to the additive manufacturing station, so that the additive tool system 15 is aligned with the surface of the substrate 14a; the inert gas protection device is turned on, and argon gas is introduced into the additive area to form an inert gas environment, effectively isolating air and preventing the metal powder from oxidizing during the deposition process;
[0045] like Figure 1 As shown in section (a), a transition layer material is deposited layer by layer on the surface of the substrate 14a using laser additive manufacturing technology through the additive tool system 15. The laser power is set to 1200W, the scanning speed is 4mm / s, and metal powder with a particle size of 60-120μm is used. The transition layer is a multi-component gradient material, which consists of the following layers from the side near the steel substrate 14a to the side near the additive body 14b: an alloy layer with Fe as the main element, and a layer with Fe as the main element. x -CoCrNiCu y An alloy layer with the composition CoCrNiCu (where the atomic ratio of Co, Cr, and Ni is 1:1:1, x ranges from 1.2, and y ranges from 1) has the following composition: CoCrNiCu. y An alloy layer with a composition of CoCrNiCu (y range 1.1) y -AI Z The alloy layer (y range 1.2, z range 2) and the alloy layer with Al as the main element are used to make the transition layer reach the design size by precisely controlling the laser parameters and powder delivery amount.
[0046] After the transition layer is deposited, the flash and burrs on the workpiece surface are cleaned to ensure a smooth surface and prepare for subsequent processing.
[0047] Preparation stage for deformation station (S200):
[0048] The additive tool system 15 is moved away; the slidable sealing workbench 13 is controlled to move to the deformation station again, so that the end punch 1 and the core punch 2 of the deformation device correspond to the mold parts on the slidable sealing workbench 13;
[0049] The end punch 1 and the core punch 2 form a closed space with the upper die 4, the left die 9 and the right die 10 on the slidable sealing workbench 13, and the vacuum system is started to extract the air in the cavity of the slidable sealing workbench 13, so that the internal absolute pressure reaches 0.02-0.04 MPa;
[0050] The pulse circuit 16 is started, and the transition layer 18 is heated through the positive and negative electrodes of the pulse circuit 16 in the axial central area of the upper die 4 and the backing plate 7. The average current density is 20 A / mm 2 , the power is 60 kW, and the temperature sensor 17 monitors the temperature of the transition layer in real time. When the temperature is lower than 450℃, the heating is continued, and when the temperature reaches the specified range (465±2℃), the heating is stopped or the heating power is adjusted to ensure that the temperature of the transition layer 18 is appropriate;
[0051] As shown in part (b) of Figure 1 , after the surface temperature of the transition layer 18 reaches the requirement, the molten aluminum or aluminum alloy is poured onto the surface of the transition layer using the pouring equipment 19 to form the billet 14 of the additive body 14b. During the pouring process, the pouring speed and the pouring amount need to be controlled to ensure that the new material can uniformly cover the surface of the transition layer and be well combined with the transition layer;
[0052] After pouring is completed, the heating is stopped, and the billet 14 of the additive body 14b is naturally cooled to the target temperature;
[0053] Multi-directional hot pressing stage (S400):
[0054] As shown in parts (c) and (d) of Figure 1 , the end punch 1, the core punch 2, the left punch 11 and the right punch 12 are used to apply multi-directional hot isostatic pressing (which belongs to multi-directional hot pressing) load to the billet 14. The end punch 1 and the core punch 2 apply pressure in the axial direction, and the left punch 11 and the right punch 12 apply pressure in the transverse direction. The pressure is 180 MPa, so that the billet 14 is compressed in multiple directions, promoting the densification of the internal organization of the material, reducing defects, and accelerating the element diffusion between the matrix 14a, the transition layer 18 and the additive body 14b, and improving the interface bonding strength. During the multi-directional hot pressing process, the material undergoes dynamic recrystallization transformation under the combined action of high temperature and pressure, so that the grain is refined and the organization is homogenized, thereby optimizing the mechanical properties of the material;
[0055] Cyclic plastic deformation stage (S500):
[0056] As shown in Figure 1As shown in the middle (e), (f) part, the control end of the punch 1 and the core punch 2 are loaded and displaced in the axial direction to form an axially open cavity; the left punch 11 and the right punch 12 are loaded and displaced in the transverse direction to form a radially open cavity, and the formation of the open cavity enables the blank 14 to be plastically deformed in a larger space; the blank 14 is deformed from the initial state to the intermediate state: the blank 14 is driven to start plastic deformation from the initial state, and its shape gradually changes to the intermediate state. The intermediate state shape of the blank 14 is mainly composed of an axially protruding structure, and the single deformation amount is controlled between the dynamic recrystallization critical deformation amount and the steady state deformation amount. The speed of metal volume transfer should meet the following conditions: (wherein h is the height of the initial state blank 14, is the material strain rate, t is the cumulative time of the blank 14 from the initial state to the intermediate state, and the strain rate is between 0.35 and 0.5);
[0057] The blank 14 is deformed from the intermediate state to the target shape: after completing the deformation from the initial state to the intermediate state, the blank 14 is continuously driven to be plastically deformed from the intermediate state to the target shape. The number of cycles of the shape of the blank 14 from the initial state to the intermediate state and then from the intermediate state to the initial state is 1-3 times. Each cycle of deformation enables the additive body 14b to experience cyclic plastic deformation, further optimizes the microstructure and performance of the additive body 14b, and improves the strength and toughness of the material.
[0058] After the deformation is completed, the pressure of each punch is unloaded, the mold is opened, and the formed workpiece is taken out from the slidable sealing workbench 13 for subsequent inspection and processing procedures.
[0059] Example 3, a steel-aluminum dissimilar material liquid-solid composite manufacturing method, based on example 1 and example 2, the steps include:
[0060] Taking a steel-aluminum dissimilar material component with a total height of 80 mm and a side length of 40 mm with a local semi-closed structure as an example, the height of the 316 stainless steel base 14a is 55 mm, the height of the additive transition layer on the surface of the base 14a is 10 mm, the depth of each dovetail groove on the transition layer is 5 mm, the bottom width is 15 mm, and the top width is 8 mm. The local semi-closed structure refers to the semi-closed structure (including the dovetail groove in this embodiment, the concave part of the component side wall) provided on the transition layer and the side wall of the steel-aluminum dissimilar material component, and then enveloping ZL101A aluminum alloy is poured on this basis.
[0061] The 316 stainless steel base 14a is placed in the lower mold; the lower mold moves together with the slidable sealing workbench 13 to the liquid phase additive working position;
[0062] The transition layer is prepared by laser melting deposition method under inert gas protection atmosphere; the laser power is 1200 W, the scanning speed is 3 mm / s, and the powder particle size is 80-100 μm; wherein the transition layer is a multi-component solid solution, and comprises the following multi-layer gradient alloy materials deposited in sequence from bottom to top:
[0063] The bottom layer is an Fe-based layer; Fe x Co, Cr, Ni, Cu contents are 25%; CoCrNiCu-A layer, Co, Cr, Ni, Cu contents (mass percent) are all 15%, and the rest of the elements is Al; the top layer is an Al-based layer;
[0064] After the transition layer with a thickness of 10 mm and a local semi-closed structure is prepared, the outer shape flash or burr is cleaned;
[0065] Moving to the deformation station and vacuumizing: moving away the additive tool: the additive tool system 15 moves away from the lower die; the lower die moves to the deformation station under the driving of the slidable sealing workbench 13; the inner cavity of the slidable sealing workbench 13 is vacuumized, and the vacuum degree is controlled between-0.08 to-0.06 MPa.
[0066] Starting the pulse circuit 16 to heat the transition layer, the average current density is 20 A / mm 2 , the power is 60 KW; when the temperature is lower than 450℃, heating is started, when the temperature is higher than 500℃, heating is stopped and temperature warning is triggered, and this heating is to 480℃;
[0067] The melt (ZL101A aluminum alloy melt) of the envelope casting additive body 14b is formed on the surface of the transition layer to form the blank 14;
[0068] The end punch 1, the core punch 2, the left punch 11 and the right punch 12 simultaneously apply multi-directional hot isostatic pressing (belonging to multi-directional hot stamping) pretreatment to the blank 14 at the target temperature, the pressure is 120 MPa, and the time is 20 min, so as to promote internal organization densification and element diffusion;
[0069] The end punch 1 and the core punch 2 respectively apply end loading load and core loading load to the blank 14 along the axial direction, and the left punch 11 and the right punch 12 respectively apply horizontal loading load to the blank 14 along the transverse direction;
[0070] The control end punch 1 and the core punch 2 are axially displaced twice to form an axially open cavity, and the left punch 11 and the right punch 12 are transversely displaced twice to form a radially open cavity. During the process, the volume of the base body 14a and the additive body 14b does not change. Under the combined loading and displacement, the billet of the additive body 14b is plastically deformed, the volume of the metal is transferred by 0.8 times of the total volume of the additive layer 14, the strain rate is controlled at 0.35, the shape of the billet 14 is deformed from the initial state to the intermediate state (the intermediate state is mainly composed of an axially protruding structure), and then from the intermediate state to the initial state, and the cycle is deformed twice to optimize the microstructure and performance of the additive body 14b.
[0071] The interface transition layer of the steel-aluminum dissimilar material component obtained in the embodiment is subjected to strength test calculation, the interface bonding strength reaches 235 MPa, the interface bonding is good, the internal quality is defect-free, and the design requirements are met.
[0072] In summary, for the steel-aluminum dissimilar material component with a total height of 80 mm, the base body 14a of the 316 stainless steel is placed in the lower mold, moved to the additive position, and prepared under the protection of inert gas with a 1200W laser and a speed of 3mm / s to form a 10mm thick multi-group element gradient transition layer. After cleaning the flash, it is moved to the deformation position, vacuumized to -0.08 to -0.06 MPa, the pulse circuit 16 is heated to 480℃, ZL101A aluminum alloy is poured, after 120MPa hot die pressing pretreatment, the multi-directional punch is loaded to make the billet 14 cyclically deformed twice, and the final interface bonding strength reaches 235 MPa, and the quality is good.
[0073] Example 4, a steel-aluminum dissimilar material liquid-solid composite manufacturing method, referring to example 3, the difference from example 3 is that Figure 3 As shown in the figure, the transition layer has a protruding part (size: length 10mm* width 10mm* height 5mm) at the bottom. The interface transition layer of the steel-aluminum dissimilar material component obtained in the embodiment is subjected to strength test calculation, the interface bonding strength reaches 242 MPa, the interface bonding is good, the internal quality is defect-free, and the design requirements are met.
[0074] Example 5, a steel-aluminum dissimilar material liquid-solid composite manufacturing method, referring to Example 3, the difference from Example 3 is that the transition layer has a protruding part (size: length 10 mm* width 10 mm* height 5 mm) at the bottom, and in the process of applying a multi-directional hot die pressing load (belonging to a local loading hot isostatic pressure) to the blank 14, the core punch 2 is controlled to impact vibration at a frequency of 180 times per second, and the vibration displacement is controlled to 2 mm. The interface transition layer of the steel-aluminum dissimilar material component obtained in this example is subjected to strength test calculation, and the interface bonding strength reaches 258 MPa (this specific hot isostatic pressure loading mode further improves the interface bonding strength of the steel-aluminum dissimilar material component), the interface is well bonded, the internal quality is defect-free, and meets the design requirements.
Claims
1. A method for manufacturing liquid-solid composite materials of steel and aluminum with a partially semi-enclosed structure, characterized in that, The manufacturing method employs a liquid-solid composite manufacturing device, which includes an additive manufacturing device and a deformation device. During different process phases, the lower molds of the additive manufacturing device and the deformation device share a sliding sealed worktable (13) in an inert atmosphere.
2. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 1, characterized in that: The upper mold of the deformation device includes an end punch (1) and a core punch (2); the sliding sealing worktable (13) includes a seat plate (8), a pad plate (7), a lower die (6), a limiting plate (5), an upper die (4), a pressure plate (3), a left die (9), a right die (10), a left punch (11), and a right punch (12); the seat plate (8) is fixed to the upper surface of the sliding sealing worktable (13); the left punch (11) passes horizontally through the limiting hole on the left side of the pad plate (7) and is fixed to the upper surface of the seat plate (8), and the right punch (12) passes horizontally through the limiting hole on the right side of the pad plate (7) and is fixed to the upper surface of the seat plate (8); the lower die... (6) Installed on the upper surface of the pad (7); the limiting plate (5) is installed on the upper surface of the lower die (6); the left die (9) and the right die (10) are located in the area between the upper surface of the lower die (6) and the limiting plate (5); the upper die (4) is installed on the upper surface of the limiting plate (5), the left die (9) and the right die (10); the pressure plate (3) is installed on the upper surface of the upper die (4); the internal space of the sliding sealing worktable (13) can be evacuated to an absolute pressure of 0.02-0.04MPa; the axial center area of the upper die (4) and the pad (7) is provided with the positive and negative poles (16) of the pulse circuit and the temperature sensor (17).
3. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 2, characterized in that: The billet (14) of dissimilar steel and aluminum materials is composed of a steel matrix (14a) and an aluminum additive body (14b); the additive body (14b) includes a transition layer (18) at the steel-aluminum interface; the matrix (14a) fits with the middle area of the lower die (6); the additive body (14b) fits with the middle area of the upper die (4); the left die (9) and the right die (10) fit with the necking area of the billet (14).
4. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 3, characterized in that, step include: S100: Place the substrate (14a) in the lower mold and move the sliding sealing worktable (13) to the additive manufacturing station; under the protection of inert gas, deposit the transition layer (18) layer by layer to the design size on the surface of the substrate (14a) through the additive tooling system (15), and clean the flash and burrs of the obtained transition layer (18); S200: Remove the additive tooling system (15), move the sliding sealing table (13) to the deformation station, and evacuate the inner cavity of the sliding sealing table (13) to a vacuum state; S300: Start the pulse circuit (16) to heat the transition layer (18) to the specified temperature, pour molten aluminum on the surface of the transition layer (18) to obtain the blank (14) of the additive body (14b). S400: Apply a multi-directional hot molding load of 100-200MPa to the blank (14) using the end punch (1), core punch (2), left punch (11), and right punch (12); S500: Control the end punch (1) and the core punch (2) to load and displace along the axial direction to form an axially open cavity (16), and control the left punch (11) and the right punch (12) to load and displace along the transverse direction to form a radially open cavity, so as to realize the plastic deformation of the blank (14) from the initial state to the intermediate state, and then from the intermediate state to the target shape.
5. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 4, characterized in that: The heating average current density of the temperature monitoring system is 15-25A / mm², and the power is 50-70kW. Heating is started when the temperature is below 450℃ and stopped when the temperature is above 500℃, triggering a temperature warning.
6. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 5, characterized in that: In the process of depositing a transition layer (18) layer by layer on the surface of the substrate (14a) using the laser additive method, the laser power is 1000-1600W, the scanning speed is 2-6mm / s, and the powder particle size is 60-120μm.
7. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 6, characterized in that, The transition layer (18) is a multi-component gradient material, and consists of the following layers sequentially from the side closer to the steel substrate (14a) to the side closer to the additive body (14b): The first layer is an alloy layer with Fe as the main element; Layer 2: Composition is Fe x -CoCrNiCu y The alloy layer has an atomic ratio of Co, Cr, and Ni of 1:1:1, where x represents the ratio of Fe atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 3, and y represents the ratio of Cu atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 1.
2. Layer 3: Composition: CoCrNiCu y The alloy layer contains Co, Cr, and Ni in an atomic ratio of 1:1:1, where y represents the ratio of Cu atoms to the total number of Co+Cr+Ni atoms, ranging from [value missing]. ; Layer 4: Composition: CoCrNiCu y -A The alloy layer contains Co, Cr, and Ni in an atomic ratio of 1:1:1, where y represents the ratio of Cu atoms to the total number of Co+Cr+Ni atoms, ranging from [value missing]. This represents the ratio of the number of Al atoms to the total number of Co+Cr+Ni atoms, ranging from 1 to 3. Layer 5: An alloy layer with AI as the main element.
8. The method for manufacturing liquid-solid composite materials of steel and aluminum according to claim 7, characterized in that: The transition layer (18) has a dovetail groove at the top and a protrusion at the bottom.
9. The method for manufacturing liquid-solid composite materials of steel and aluminum according to any one of claims 4-8, characterized in that: During the process of applying multi-directional hot mold pressure load to the blank (14), the core punch (2) is controlled to impact vibration at a frequency of 180 times per second, and the vibration displacement is controlled to be 2mm.