Aerospace aluminum alloy component fusion manufacturing process

Abstract

The application relates to the field of aerospace manufacturing, and particularly discloses a kind of aerospace aluminum alloy component fusion manufacturing processes, comprising the following steps: S1, using SLM or LMD additive manufacturing technology to obtain preform;S2, the preform is subjected to preliminary subtractive machining, removes the region with surface roughness of 5-10 mu m, and reserves the finishing allowance of 0.1-0.2 mm;S3, segmented heat treatment, first stress relief annealing is carried out, then solid solution treatment is carried out, and finally double-pole aging treatment is carried out;S4, precision cutting, precision cutting processing is carried out, and an aerospace aluminum alloy component is obtained.The application has the characteristics of realizing efficient and high-quality manufacturing of aerospace aluminum alloy components, reducing manufacturing cost, obtaining component size precision of ≤±0.1 mm, surface roughness of ≤Ra 0.8 mu m, and better mechanical property stability, and room temperature tensile strength fluctuation of ≤±5 MPa.

Description

Technical Field

[0001] This application relates to the field of aerospace manufacturing, and more specifically, it relates to a fusion manufacturing process for aerospace aluminum alloy components. Background Technology

[0002] Aerospace aluminum alloy components such as 2024Al, 2219Al, and 7075Al play a core role in key structures such as aerospace engine components, spacecraft control arms, and instrument compartments due to their high strength, lightweight, corrosion resistance, and high temperature resistance. They are key materials for improving the performance, reliability, and economy of spacecraft.

[0003] The traditional manufacturing process for the aforementioned aerospace aluminum alloy components typically employs a multi-stage machining process: "casting billet preparation → forging billet preparation → rough machining → heat treatment → semi-finishing → finishing." However, this process has the following significant drawbacks:

[0004] 1) Low material utilization: During the casting and forging processes, the material removal rate reaches 70-80% (e.g., in the manufacture of instrument housing shells, the blank weight is 100kg, and the finished product weight is only 20-30kg), resulting in serious material waste;

[0005] 2) Long manufacturing cycle: Traditional processes involve multiple steps, each requiring separate tooling preparation and parameter adjustment, resulting in a manufacturing cycle of 2-3 months. For example, the manufacturing of support rudder arms takes 60-90 days from raw material to finished product, which cannot meet the rapid development requirements of aerospace equipment.

[0006] 3) High cost: High material removal rate leads to increased raw material costs, and multiple processing steps result in a significant increase in equipment energy consumption and labor costs. The manufacturing cost of traditional processes is about 800-1000 yuan / kg.

[0007] 4) Insufficient performance stability: Forging processes are prone to problems such as uneven grain size and stress concentration. These problems may be further aggravated during subsequent heat treatment, leading to large fluctuations in the mechanical properties of the components, with room temperature tensile strength fluctuations reaching ±20 MPa. Some components require rework due to performance instability, which not only increases manufacturing costs but also prolongs the production cycle.

[0008] With the transformation and upgrading of the manufacturing industry, integrated manufacturing processes combining additive manufacturing, subtractive manufacturing, and other technologies have become a new direction. However, aerospace aluminum alloy components have stringent requirements for manufacturing precision and performance, with dimensional accuracy ≤ ±0.1mm, surface roughness ≤ Ra 0.8μm, and room temperature tensile strength fluctuation ≤ ±5MPa. Existing integrated manufacturing technologies are unable to meet these requirements. Therefore, there is an urgent need to develop a new integrated manufacturing process to achieve efficient and high-quality manufacturing of aerospace aluminum alloy components. Summary of the Invention

[0009] In order to achieve efficient and high-quality manufacturing of aerospace aluminum alloy components, reduce manufacturing costs, and produce components with dimensional accuracy ≤ ±0.1 mm, surface roughness ≤ Ra 0.8 μm, better mechanical property stability, and room temperature tensile strength fluctuation ≤ ±5 MPa, this application provides an aerospace aluminum alloy component fusion manufacturing process.

[0010] This application provides a fusion manufacturing process for aerospace aluminum alloy components, employing the following technical solution:

[0011] A process for fusing aerospace aluminum alloy components includes the following steps:

[0012] S1. Preforms are produced using SLM or LMD additive manufacturing technology;

[0013] S2. Perform preliminary subtractive processing on the preformed part to remove areas with a surface roughness of 5-10μm, and leave a finishing allowance of 0.1-0.2mm;

[0014] S3. Segmented heat treatment: First, stress relief annealing is performed at 180-200℃ for 1.5-2.5h, then water quenching is performed at 480-500℃ for 1-2h, followed by solution treatment, and finally bipolar aging treatment is performed at 120-130℃ for 2-3h, followed by heating to 160-170℃.

[0015] S4. Precision cutting: Precision cutting is performed to produce aerospace aluminum alloy components.

[0016] By adopting the above technical solutions, this application employs SLM or LMD additive manufacturing technologies. SLM uses a high-power laser to melt metal powder layer by layer to form complex structures, resulting in high material utilization. LMD, on the other hand, uses laser melting and simultaneous powder feeding to achieve near-net-shape rapid manufacturing. The preforms obtained through additive manufacturing have high surface roughness and may contain residual stress. Direct finishing can easily lead to deformation or cracks. Therefore, in this application, preliminary subtractive processing is performed after additive manufacturing to remove areas with high surface roughness, eliminate surface defects, and reserve finishing allowances. This provides adjustment space for subsequent precision cutting, avoids dimensional deviations due to heat treatment, reduces subsequent processing risks, and ensures the dimensional stability of the components after heat treatment.

[0017] After initial subtractive processing, segmented heat treatment is performed to optimize microstructure and eliminate residual stress. More specifically, stress-relief annealing is first performed to eliminate residual stress generated during additive manufacturing and prevent deformation during subsequent processing. Then, solution treatment is performed to melt alloying elements into the matrix to form a supersaturated solid solution. Next, bipolar aging treatment is performed to induce uniform precipitation of strengthening phases by precipitating fine dispersed phases through graded aging, thereby improving strength. After heat treatment, the component may undergo slight deformation due to microstructural transformation. Finally, precision cutting is performed to ensure that the final dimensional accuracy and surface quality of the component meet aerospace standards.

[0018] Ultimately, the integrated manufacturing process provided in this application significantly improves material utilization, increasing it from 20-30% in traditional processes to 80-90%, reducing material waste and lowering raw material costs. The manufacturing cycle is significantly shortened, from 2-3 months in traditional processes to 15-20 days, meeting the rapid development needs of aerospace equipment. It offers significant cost advantages; for example, the cost of a 2024Al support arm using traditional processes is 800 RMB / kg, while the process provided in this application costs only 600 RMB / kg, reducing manufacturing costs by 20-30%. It boasts excellent precision and performance, with component dimensional accuracy ≤0.1mm, surface roughness ≤Ra0.8μm, and room temperature tensile strength fluctuation ≤±5MPa, meeting the requirements for aerospace equipment installation. It exhibits strong process synergy, with additive manufacturing, subtractive manufacturing, and heat treatment processes optimized synergistically to avoid quality fluctuations between processes and improve manufacturing stability. It has broad applicability, suitable for various aerospace aluminum alloy components such as 2024Al, 2219Al, and 7075Al.

[0019] Optionally, in step S1, the thin-walled component is manufactured using SLM additive manufacturing with the following process parameters: laser power of 180-220W, scanning speed of 800-1200mm / s, layer thickness of 20-40μm, 90° cross scanning between adjacent layers during scanning, and substrate preheating temperature of 100-150℃.

[0020] By adopting the above technical solutions, in SLM (Selective Laser Melting) additive manufacturing, the selection of laser power ensures density and avoids under-melting. Too low a power will lead to insufficient powder melting, forming pores or unfused defects, while too high a power will cause overheating, resulting in grain coarsening, thermal stress concentration, and even damage to the substrate. The control of scanning speed can control grain size and suppress cracks. The layer thickness balances forming efficiency and accuracy, while the cross-scanning strategy disperses thermal stress and reduces deformation. The control of substrate preheating temperature can reduce thermal stress and avoid cracking.

[0021] Optionally, in step S1, the thick-walled component is manufactured using LMD additive manufacturing with the following process parameters: laser power of 180-220W, scanning speed of 300-500mm / s, powder feeding rate of 20-40g / min, spot diameter of 2-4mm, and argon atmosphere.

[0022] By adopting the above technical solutions, during LMD (laser metal deposition) additive manufacturing, the laser power is adjusted to ensure that the deposited layer is fully melted. LMD uses synchronous powder feeding technology, and the laser power needs to melt the powder and the substrate surface at the same time. If the power is too low, the powder will not melt sufficiently, forming spheroids or pores. If the power is too high, it may cause spatter and reduce the deposition efficiency. The scanning speed is adjusted to control the cooling rate and refine the grains, while the powder feeding rate is matched with the scanning speed to ensure uniform layer thickness. The spot diameter parameter improves the forming efficiency, and the argon atmosphere is controlled to prevent oxidation.

[0023] Optionally, the parameters for the initial subtractive machining in step S2 are: cutting speed of 1000-1500 m / min, feed rate of 0.1-0.2 mm / r, and depth of cut of 0.3-0.8 mm.

[0024] By adopting the above technical solutions, machining efficiency is ensured by adjusting the cutting speed, work hardening is avoided, surface roughness is controlled by the feed rate to avoid vibration marks, and most of the allowance is removed by the depth of cut, leaving room for finishing.

[0025] Optionally, the precision cutting parameters in step S4 are: cutting speed of 1500-2000 m / min, feed rate of 0.05-0.1 mm / r, depth of cut of 0.1-0.2 mm, and cooling method of oil mist cooling.

[0026] By adopting the above technical solutions, the control of cutting speed improves surface quality and reduces machining defects, the control of feed rate controls the surface roughness to ≤Ra0.8μm, the control of depth of cut removes the reserved allowance and ensures dimensional accuracy, and finally the use of oil mist cooling reduces the cutting temperature and avoids surface burn.

[0027] Optionally, in step S3, for the 2024Al alloy component, the specific operation of the segmented heat treatment is as follows: first, stress relief annealing is performed at 200℃ for 2 hours, then water quenching is performed at 495℃ for 1.5 hours, followed by solution treatment, and finally bipolar aging treatment is performed at 130℃ for 3 hours and then heated to 170℃ for 7 hours.

[0028] By adopting the above technical solution, for 2024Al alloy components, the first stage of stress-relief annealing can eliminate processing stress, then the second stage of solution treatment dissolves the low-melting-point phase at the grain boundaries, and finally the bipolar aging treatment induces the precipitation of strengthening phases.

[0029] Optionally, in step S3, for the 7075Al alloy component, the specific operation of the segmented heat treatment is as follows: first, stress relief annealing is performed at 180℃ for 2 hours, then water quenching is performed at 480℃ for 2 hours, followed by solution treatment, and finally bipolar aging treatment is performed at 120℃ for 2 hours and then heated to 160℃ for 8 hours.

[0030] By adopting the above technical solution, for 7015Al alloy components, the first stage of stress-relief annealing can eliminate processing stress, then the second stage of solution treatment can homogenize solute elements, and finally the bipolar aging treatment can induce the precipitation of η' phase.

[0031] Optionally, in step S3, a pulsed magnetic field is applied synchronously during the bipolar aging process, with a magnetic field strength of 1-3T and a pulse frequency of 20-40Hz.

[0032] By adopting the above technical solution, the pulsed magnetic field generates a dynamic stress field inside the aluminum alloy through magnetostriction and alternating magnetic force. This stress field is superimposed with the thermal field, promoting dislocation movement and providing more nucleation sites for precipitates. Furthermore, the eddy current response of the pulsed magnetic field accelerates phase transformation while suppressing the formation of coarse precipitates, thus achieving microstructure refinement. Moreover, the application of the pulsed magnetic field can significantly accelerate the aging process while improving mechanical properties.

[0033] Optionally, when using SLM or LMD additive manufacturing in step S1, CuO micro powder is injected simultaneously during the laser cladding process, and the amount of CuO micro powder added is 0.05-0.1 wt% of the matrix powder.

[0034] By adopting the above technical solution, CuO micro powder is simultaneously injected during the laser cladding process. It is reduced to Cu atoms at the high temperature of the molten pool and reacts with Al atoms to generate nanoscale Al2Cu phase. The dispersed distribution of nanoscale Al2Cu reinforcing phase in the aluminum alloy matrix can significantly hinder the movement of dislocations and improve the mechanical properties of the component. Moreover, the nanoscale reinforcing phase promotes grain refinement, which helps to reduce stress concentration. This refinement effect can be stabilized during the heat treatment or long-term use of the component, thereby improving the stability of mechanical properties.

[0035] Optionally, when using SLM or LMD additive manufacturing in step S1, ZrH2 micro powder is injected simultaneously during the laser cladding process, and the amount of ZrH2 micro powder added is 0.03-0.05 wt% of the matrix powder.

[0036] By employing the above technical solution, ZrH2 decomposes at high temperatures in the molten pool, releasing Zr atoms, which react with Al atoms in the aluminum alloy matrix to form nanoscale Al3Zr phases. These nanoscale Al3Zr reinforcing phases can act as nucleation sites for heterogeneous formation, promoting grain refinement. The fine grain structure improves the strength and toughness of the aluminum alloy, while also helping to reduce stress concentration and enhance its crack resistance. This grain refinement effect remains stable during heat treatment or long-term use, thus ensuring the stability of mechanical properties.

[0037] Optionally, ZrH2 micro powder is prepared by reducing zirconium dioxide at 600°C in a hydrogen stream using calcium hydride as a reducing agent.

[0038] In summary, this application has the following beneficial effects:

[0039] This application provides a manufacturing process that significantly improves material utilization from 20-30% in traditional processes to 80-90%, reducing material waste and lowering raw material costs. The manufacturing cycle is significantly shortened from 2-3 months in traditional processes to 15-20 days, meeting the rapid development needs of aerospace equipment. It offers a clear cost advantage; for example, the cost of a 2024Al support arm using traditional processes is 800 RMB / kg, while the process provided in this application costs only 600 RMB / kg, reducing manufacturing costs by 20-30%. It also boasts excellent precision and performance, with component dimensional accuracy ≤0.1mm, surface roughness ≤Ra0.8μm, and room temperature tensile strength fluctuation ≤±5MPa, meeting the requirements for aerospace equipment installation. Furthermore, it exhibits strong process synergy, with additive manufacturing, subtractive manufacturing, and heat treatment processes optimized synergistically to avoid quality fluctuations between processes and improve manufacturing stability. Finally, it has broad applicability, suitable for various aerospace aluminum alloy components such as 2024Al, 2219Al, and 7075Al. Detailed Implementation

[0040] The following detailed description of this application is provided in conjunction with the embodiments. It should be noted that: unless otherwise specified, the conditions in the following embodiments are performed under conventional conditions or conditions recommended by the manufacturer. Unless otherwise specified, the raw materials used in the following embodiments are all from commercially available sources.

[0041] In the following examples, the metal powder of the 2024Al alloy raw material includes the following elements by mass percentage: 4.4% Cu, 1.5% Mg, 0.6% Mn and the balance Al;

[0042] In the following examples, the metal powder of the 7075Al alloy raw material includes the following elements by mass percentage: 5.6% Zn, 2.5% Mg, 1.6% Cu, 0.23% Cr and the balance Al.

[0043] In the following examples, ZrH2 micro powder was prepared by reducing zirconium dioxide at 600°C in a hydrogen stream using calcium hydride as a reducing agent.

[0044] Example 1

[0045] A process for integrating aerospace aluminum alloy components is disclosed. In this embodiment, the aluminum alloy component is specifically a 2024Al alloy aerospace support rudder arm. The design requirements for the 2024Al alloy aerospace support rudder arm component in this embodiment are as follows: the support rudder arm size is 200mm×50mm, the 2024Al alloy aerospace support rudder arm is 30mm, the wall thickness is 10mm, the dimensional accuracy of the key surface (connection hole) is ±0.05mm, and the surface roughness Ra is 0.4μm.

[0046] Its integrated manufacturing process specifically includes the following steps:

[0047] S1, SLM Preforming: Using 2024Al alloy metal powder as the raw material for SLM, SLM additive manufacturing was performed using an SLM-S300 selective laser melting equipment. The process parameters were: laser power 200W, scanning speed 1000mm / s, layer thickness 30μm, 90° cross scanning between adjacent layers, substrate preheating to 120℃, and the process was carried out in an argon protective atmosphere (oxygen content 0.08%). The preformed part was obtained with dimensions of 201mm×51mm×31mm (1mm allowance) and a density of 99.8%.

[0048] S2. Perform preliminary subtractive machining on the preform to remove areas with a surface roughness of 5-10μm, leaving a finishing allowance of 0.2mm. The equipment used is a DMG MORI DMC 635 V vertical machining center, with the following process parameters: cutting speed 1200m / min, feed rate 0.15mm / r, depth of cut 0.5mm, and the cutting tool is an 8mm diameter carbide end mill. The dimensions after preliminary subtractive machining are 200.2mm×50.2mm×30.2mm (with a 0.2mm allowance), and the surface roughness Ra is 2.0μm.

[0049] S3. Segmented heat treatment: First, stress-relief annealing is performed at 200℃ for 2 hours (residual stress reduced to 45MPa). Then, water quenching is performed after treatment at 495℃ for 1.5 hours, followed by solution treatment. Finally, bipolar aging treatment is performed after treatment at 130℃ for 3 hours and then heated to 170℃ for 7 hours. After segmented heat treatment, the preform is characterized by EBSD: equiaxed crystal ratio is 92%, and grain size is 304μm.

[0050] S4. Precision cutting: Precision cutting is performed with the following process parameters: cutting speed 1800 m / min, feed rate 0.08 mm / r, depth of cut 0.15 mm, and oil mist cooling (pressure 0.3 MPa). Then, key surface machining is performed, specifically the connection hole is machined using a reamer (reamer diameter 10 mm, feed rate H7). The machined dimensions are 200 mm × 50 mm × 30 mm, with a dimensional deviation of ±0.08 mm and a surface roughness Ra of 0.3 μm, resulting in an aluminum alloy component.

[0051] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 415 MPa, the tensile strength was 460 MPa, and the elongation was 11%. In 5 parallel tests, the yield strength and tensile strength fluctuated by ±4 MPa.

[0052] In addition, non-destructive testing was conducted, using industrial CT and ultrasonic testing to detect no defects;

[0053] Cost and cycle: In this embodiment, the material utilization rate is 85%, the manufacturing cost is 600 yuan / kg, and the manufacturing cycle is 18 days. Compared with the traditional process (casting billet → forging billet → rough machining → heat treatment → semi-finishing → finishing) which has a cycle of 60 days and a cost of 800 yuan / kg, the cost and processing cycle are significantly reduced.

[0054] Example 2

[0055] A fusion manufacturing process for aerospace aluminum alloy components, specifically a 7075Al alloy engine blade in this embodiment. The 7075Al alloy engine blade is designed with dimensions of 300mm × 80mm × 20mm, a wall thickness of 5mm, and a surface roughness Ra of 0.8μm. The fusion manufacturing process includes the following steps:

[0056] S1. LMD Pre-forming: Using 7075Al alloy metal powder as the raw material for LMD, LMD additive manufacturing is performed using an LMD-1000 laser metal deposition equipment. The process parameters are: laser power 1000W, scanning speed 400mm / min, powder feed rate 30g / min, spot diameter 3mm, and the process is carried out in an argon protective atmosphere (oxygen content 0.09%). A pre-formed part is obtained, with dimensions of 201mm×51mm×31mm (1mm margin) and a density of 99.8%.

[0057] S2. Perform preliminary subtractive machining on the preformed part to remove areas with a surface roughness of 5-10μm, leaving a finishing allowance of 0.2mm. The equipment used is a DMG MORI DMC 635 V vertical machining center, with the following process parameters: cutting speed 1000m / min, feed rate 0.15mm / r, depth of cut 0.5mm, and the cutting tool type is an 8mm diameter carbide end mill. The dimensions after preliminary subtractive machining are 300.2mm × 80.2mm × 20.2mm (with a 0.2mm allowance).

[0058] S3. Segmented heat treatment: First, stress relief annealing is performed at 180℃ for 2 hours, then water quenching is performed at 480℃ for 2 hours for solution treatment, and finally bipolar aging treatment is performed at 120℃ for 2 hours and then heated to 160℃ for 8 hours.

[0059] S4. Precision cutting: Perform precision cutting processing with the following parameters: cutting speed 1600 m / min, feed rate 0.06 mm / r, depth of cut 0.15 mm, and cooling method: oil mist cooling (pressure 0.3 MPa). The dimensions after machining are 300 mm × 80 mm × 20 mm, with a dimensional deviation of ±0.05 mm and a surface roughness Ra of 0.8 μm, resulting in an aluminum alloy component.

[0060] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 530 MPa, the tensile strength was 605 MPa, and the elongation was 9%. In 5 parallel tests, the yield strength and tensile strength fluctuated by ±3 MPa.

[0061] In addition, non-destructive testing was conducted, using industrial CT and ultrasonic testing to detect no defects;

[0062] Cost and cycle: In this embodiment, the material utilization rate is 88% and the manufacturing cycle is 16 days. Compared with the traditional process (casting billet → forging billet → rough machining → heat treatment → semi-finishing → finishing) cycle of 60 days, the cost and processing cycle are significantly reduced.

[0063] Example 3

[0064] A fusion manufacturing process for aerospace aluminum alloy components is carried out according to the method in Example 1, except that in step S1, the laser power is 180W, the scanning speed is 800mm / s, the layer thickness is 20μm, and the substrate preheating temperature is 100℃.

[0065] In step S2, during the initial subtraction machining process, the cutting speed is 1000 m / min, the feed rate is 0.1 mm / r, and the depth of cut is 0.3 mm.

[0066] In step S4, during precision cutting, the cutting speed is 1500 m / min, the feed rate is 0.05 mm / r, the depth of cut is 0.10 mm, and the cooling method is oil mist cooling (pressure 0.3 MPa).

[0067] In this embodiment, the final metal component has a dimensional deviation of ±0.06mm and a surface roughness Ra of 0.4μm, and the resulting aluminum alloy component meets the requirements.

[0068] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 412 MPa, the tensile strength was 457 MPa, and the elongation was 10%. In 5 parallel tests, the yield strength and tensile strength fluctuated by ±4.5 MPa.

[0069] Example 4

[0070] A fusion manufacturing process for aerospace aluminum alloy components is carried out according to the method in Example 1, except that in step S1, the laser power is 220W, the scanning speed is 1200mm / s, the layer thickness is 40μm, and the substrate preheating temperature is 150℃.

[0071] In step S2, during the initial subtraction machining process, the cutting speed is 1500 m / min, the feed rate is 0.2 mm / r, and the depth of cut is 0.8 mm.

[0072] In step S4, during precision cutting, the cutting speed is 2000 m / min, the feed rate is 0.1 mm / r, the depth of cut is 0.20 mm, and the cooling method is oil mist cooling (pressure 0.3 MPa).

[0073] In this embodiment, the final metal component has a dimensional deviation of ±0.09mm and a surface roughness Ra of 0.4μm, and the resulting aluminum alloy component meets the requirements.

[0074] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 410 MPa, the tensile strength was 450 MPa, and the elongation was 10%. In 5 parallel tests, the yield strength and tensile strength fluctuated by ±4.8 MPa.

[0075] Example 5

[0076] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 2, except that in step S1, the laser power is 800W, the scanning speed is 300mm / min, the powder feeding rate is 20g / min, the spot diameter is 2mm, and the process is carried out in an argon protective atmosphere (oxygen content 0.08%).

[0077] In this embodiment, the final metal component has a dimensional deviation of ±0.06mm and a surface roughness Ra of 0.7μm, and the resulting aluminum alloy component meets the requirements.

[0078] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 523 MPa, the tensile strength was 596 MPa, and the elongation was 10%. In 5 parallel tests, the yield strength and tensile strength fluctuated by ±3.5 MPa.

[0079] Example 6

[0080] A fusion manufacturing process for aerospace aluminum alloy components is carried out according to the method in Example 2, except that in step S1, the laser power is 1200W, the scanning speed is 500mm / min, the powder feeding rate is 40g / min, the spot diameter is 4mm, and the process is carried out in an argon protective atmosphere (oxygen content 0.08%).

[0081] In this embodiment, the final metal component has a dimensional deviation of ±0.07mm and a surface roughness Ra of 0.9μm, and the resulting aluminum alloy component meets the requirements.

[0082] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 520 MPa, the tensile strength was 591 MPa, and the elongation was 11%. In 5 parallel tests, the yield strength and tensile strength fluctuated by ±4 MPa.

[0083] Example 7

[0084] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 1, except that in step S3, a pulsed magnetic field is applied simultaneously during the bipolar aging treatment. The magnetic field strength is 2T and the pulse frequency is 30Hz. During the bipolar aging treatment, the temperature is raised to 170℃ and treated for 4 hours.

[0085] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 430 MPa, the tensile strength was 482 MPa, and the elongation was 12%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2.6 MPa. In addition, no defects were found in the non-destructive testing.

[0086] Example 8

[0087] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 1, except that in step S3, a pulsed magnetic field is applied simultaneously during the bipolar aging treatment. The magnetic field strength is 1T and the pulse frequency is 20Hz. During the bipolar aging treatment, the temperature is raised to 170℃ and treated for 5 hours.

[0088] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 422 MPa, the tensile strength was 472 MPa, and the elongation was 10%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±3.0 MPa. In addition, no defects were found in the non-destructive testing.

[0089] Example 9

[0090] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 1, except that in step S3, a pulsed magnetic field is applied simultaneously during the bipolar aging treatment. The magnetic field strength is 3T and the pulse frequency is 40Hz. During the bipolar aging treatment, the temperature is raised to 170℃ and treated for 3.5h.

[0091] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 426 MPa, the tensile strength was 476 MPa, and the elongation was 11%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2.8 MPa. In addition, no defects were found in the non-destructive testing.

[0092] Example 10

[0093] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 2, except that in step S3, a pulsed magnetic field is applied simultaneously during the bipolar aging treatment. The magnetic field strength is 2T and the pulse frequency is 30Hz. During the bipolar aging treatment, the temperature is raised to 160℃ and treated for 5 hours.

[0094] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 542 MPa, the tensile strength was 621 MPa, and the elongation was 10%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2 MPa. In addition, no defects were found in the non-destructive testing.

[0095] Example 11

[0096] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 1. The difference is that when using SLM additive manufacturing in step S1, CuO micro powder and ZrH2 micro powder are pre-mixed with metal powder and used as raw materials for SLM additive manufacturing. The amount of CuO micro powder added is 0.08 wt% of the metal powder, and the amount of ZrH2 micro powder added is 0.04 wt% of the metal powder.

[0097] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 448 MPa, the tensile strength was 495 MPa, and the elongation was 13%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2 MPa. In addition, no defects were found in the non-destructive testing.

[0098] Example 12

[0099] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 1. The difference is that when using SLM additive manufacturing in step S1, CuO micro powder and ZrH2 micro powder are pre-mixed with metal powder and used as raw materials for SLM additive manufacturing. The amount of CuO micro powder added is 0.05 wt% of the metal powder, and the amount of ZrH2 micro powder added is 0.03 wt% of the metal powder.

[0100] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 445 MPa, the tensile strength was 490 MPa, and the elongation was 12%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2.3 MPa. In addition, no defects were found in the non-destructive testing.

[0101] Example 13

[0102] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 1. The difference is that when using SLM additive manufacturing in step S1, CuO micro powder and ZrH2 micro powder are pre-mixed with metal powder and used as raw materials for SLM additive manufacturing. The amount of CuO micro powder added is 0.1 wt% of the metal powder, and the amount of ZrH2 micro powder added is 0.05 wt% of the metal powder.

[0103] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 446 MPa, the tensile strength was 492 MPa, and the elongation was 13%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2.1 MPa. In addition, no defects were found in the non-destructive testing.

[0104] Example 14

[0105] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 11, except that ZrH2 micro powder is not added, but CuO micro powder is premixed with metal powder and used as raw material for SLM additive manufacturing.

[0106] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 430 MPa, the tensile strength was 478 MPa, and the elongation was 12%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±3 MPa. In addition, non-destructive testing showed no defects.

[0107] Example 15

[0108] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 11, except that CuO micro powder is not added, but ZrH2 micro powder is premixed with metal powder and used as raw material for SLM additive manufacturing.

[0109] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 432 MPa, the tensile strength was 481 MPa, and the elongation was 12%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±2.8 MPa. In addition, non-destructive testing showed no defects.

[0110] Example 16

[0111] A process for fusion manufacturing of aerospace aluminum alloy components is carried out according to the method in Example 2. The difference is that when using LMD additive manufacturing in step S1, CuO micro powder and ZrH2 micro powder are pre-mixed with metal powder and used as raw materials for LMD additive manufacturing. The amount of CuO micro powder added is 0.08 wt% of the metal powder, and the amount of ZrH2 micro powder added is 0.04 wt% of the metal powder.

[0112] The aluminum alloy component prepared in the embodiments of this application was subjected to a room temperature tensile test. The yield strength was 552 MPa, the tensile strength was 633 MPa, and the elongation was 11%. Five parallel tests were conducted. The yield strength and tensile strength fluctuated by ±1.5 MPa. In addition, no defects were found in the non-destructive testing.

[0113] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A fusion manufacturing process for aerospace aluminum alloy components, characterized in that, Includes the following steps: S1. Preforms are produced using SLM or LMD additive manufacturing technology; S2. Perform preliminary subtractive processing on the preformed part to remove areas with a surface roughness of 5-10μm, leaving a finishing allowance of 0.1-0.2mm; S3. Perform segmented heat treatment: first, stress-relieving annealing at 180-200℃ for 1.5-2.5h, then water quenching at 480-500℃ for 1-2h for solution treatment, and finally bipolar aging treatment at 120-130℃ for 2-3h, followed by heating to 160-170℃; S4. Perform precision cutting to obtain aerospace aluminum alloy components; In step S1, when using SLM or LMD additive manufacturing, CuO micro powder and metal powder are pre-mixed and used as raw materials for SLM or LMD additive manufacturing. The amount of CuO micro powder added is 0.05-0.1 wt% of the metal powder. Alternatively, when using SLM or LMD additive manufacturing in step S1, ZrH2 micro powder and metal powder are premixed and used as raw materials for SLM or LMD additive manufacturing, with the amount of ZrH2 micro powder added being 0.03-0.05 wt% of the metal powder.

2. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: In step S1, the thin-walled component is manufactured using SLM additive manufacturing. The process parameters are: laser power of 180-220W, scanning speed of 800-1200mm / s, layer thickness of 20-40μm, 90° cross scanning between adjacent layers during scanning, and substrate preheating temperature of 100-150℃.

3. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: In step S1, the thick-walled component is manufactured using LMD additive manufacturing. The process parameters are: laser power of 180-220W, scanning speed of 300-500mm / s, powder feeding rate of 20-40g / min, spot diameter of 2-4mm, and protective atmosphere of argon.

4. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: The parameters for the initial subtraction machining in step S2 are: cutting speed of 1000-1500 m / min, feed rate of 0.1-0.2 mm / r, and depth of cut of 0.3-0.8 mm.

5. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: The precision cutting parameters in step S4 are: cutting speed of 1500-2000 m / min, feed rate of 0.05-0.1 mm / r, depth of cut of 0.1-0.2 mm, and cooling method of oil mist cooling.

6. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: In step S3, for the 2024Al alloy component, the specific operation of the segmented heat treatment is as follows: first, stress relief annealing is performed at 200℃ for 2 hours, then water quenching is performed after treatment at 495℃ for 1.5 hours, followed by solution treatment, and finally bipolar aging treatment is performed after treatment at 130℃ for 3 hours and then heating to 170℃ for 7 hours.

7. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: In step S3, for the 7075Al alloy component, the specific operation of segmented heat treatment is as follows: first, stress relief annealing is performed at 180℃ for 2 hours, then water quenching is performed at 480℃ for 2 hours, followed by solution treatment, and finally bipolar aging treatment is performed at 120℃ for 2 hours and then heated to 160℃ for 8 hours.

8. The aerospace aluminum alloy component fusion manufacturing process according to claim 1, characterized in that: In step S3, a pulsed magnetic field is applied synchronously during the bipolar aging process, with a magnetic field strength of 1-3T and a pulse frequency of 20-40Hz.