Ultrasonic-assisted double-wire consumable electrode-non-consumable electrode electric arc additive manufacturing device and method
The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing device solves the problems of grain coarsening and anisotropy caused by overheating in arc additive manufacturing, achieving efficient grain refinement and improved mechanical properties. It is applicable to the additive manufacturing of various metal materials.
Patent Information
- Application Number
- CN202610421470.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-04-01
- Publication Date
- 2026-05-15
AI Technical Summary
In existing electric arc additive manufacturing methods, the overheating caused by the welding arc leads to the formation of coarse columnar crystal structures that grow along the building direction in the additively manufactured parts, resulting in anisotropy in microstructure and mechanical properties, which affects the quality of the parts.
An ultrasonic-assisted dual-wire fused electrode-non-fused electrode additive manufacturing device is used. Non-contact ultrasonic waves are applied to the deposited layer, combined with the dual-wire fused electrode-non-fused electrode arc, to reduce heat input, refine grains, and improve microstructure anisotropy.
It significantly reduces the heat input of the deposited layer, refines the grains, improves mechanical properties, increases deposition rate and productivity, and is suitable for additive manufacturing of a variety of metal materials.
Smart Images
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Abstract
Description
Technical Field
[0001] This invention relates to the field of electric arc additive manufacturing technology, specifically to an ultrasonic-assisted dual-wire fused electrode-non-fused electrode electric arc additive manufacturing apparatus and method. Background Technology
[0002] Arc additive manufacturing is an additive manufacturing method that uses an electric arc as a heat source to melt filaments and deposits them layer by layer according to a pre-planned path to produce products. It has many advantages such as high deposition rate, low production cost, high material utilization rate and flexible parameter adjustment. Compared with additive manufacturing methods that use high-energy beams such as lasers or electron beams as heat sources and powders as raw materials, it has obvious advantages in manufacturing large and medium-sized components.
[0003] However, the following problems still exist: Currently used arc additive manufacturing methods are based on traditional welding arcs, generally including metal inert gas / metal active gas (MIG / MAG) arcs and non-consumable electrode arcs, the latter including TIG arcs (Tungsten Inert Gas Arc) and PA (Plasma Arc), etc. Since these are arc heat sources used for welding, directly using them as heat sources for additive manufacturing will inevitably overheat the substrate and deposited layer in addition to heating the wire. Due to layer-by-layer deposition, this overheating further accumulates, resulting in coarse columnar crystal structures growing along the construction direction in the additive manufactured parts. This leads to anisotropy in microstructure and mechanical properties, becoming one of the key factors restricting the quality of additive manufactured parts.
[0004] To reduce heat input, current methods include Cold Metal Transfer (CMT), hot-wire TIG arc, pulsed TIG arc, pulsed MIG / MAG arc, indirect arc, and bypass arc. Another approach is multi-wire melting deposition, such as dual-wire MIG arc, cold-wire + CMT, and dual-wire TIG arc. These methods increase the amount of metal melted per unit heat, effectively reducing the heat input during deposition. While these methods reduce heat input to varying degrees and improve the mechanical properties of additive parts, they all directly utilize the welding arc, resulting in a significant amount of arc heat acting on the deposited layer, thus failing to completely avoid overheating.
[0005] Based on this, the present invention provides an ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus and method. Summary of the Invention
[0006] To address the shortcomings of existing technologies, this invention provides an ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus and method, which completely avoids excessive heating of the deposited layer. Simultaneously, the use of dual wires significantly improves the melting and deposition efficiency of the wires, further leveraging the advantages of the arc additive manufacturing method. This solves the problems in the prior art, such as the inability to completely avoid excessive heating of the deposited layer by the arc and (or molten droplets), and the resulting increase in equipment costs. Furthermore, the use of non-contact ultrasonic waves on the deposited layer further refines the grains, improves microstructure anisotropy, and enhances mechanical properties; it also overcomes the drawback of contact ultrasonic waves where the ultrasonic effect gradually weakens layer by layer as the substrate acts on the molten deposited layer.
[0007] This invention provides the following technical solution: an ultrasonic-assisted dual-wire consumable electrode-non-consumable electrode arc additive manufacturing device, comprising: a power supply, a power supply, a wire feeder, a wire feeder, a non-consumable electrode welding torch, a non-consumable electrode welding torch, a conductive nozzle, a conductive nozzle, a wire, a wire clamping mechanism, a welding torch clamping mechanism, an ultrasonic head clamping mechanism, and an ultrasonic system;
[0008] The ultrasonic system includes an ultrasonic generating system and an ultrasonic head;
[0009] The non-consumable electrode welding torch one and the non-consumable electrode welding torch two are fixed by the welding torch clamping mechanism. The wire one and the wire two are clamped by the wire clamping mechanism. The wire clamping mechanism is connected to the non-consumable electrode welding torch one and the non-consumable electrode welding torch two. The ultrasonic head clamping mechanism is rigidly connected to the welding torch clamping mechanism. The ultrasonic head is fixed by the ultrasonic head clamping mechanism.
[0010] The first non-consumable electrode welding torch is connected to the negative terminal of the first power supply, and the second non-consumable electrode welding torch is connected to the negative terminal of the second power supply; the first wire is connected to the positive terminal of the first power supply through the first conductive nozzle, and the second wire is connected to the positive terminal of the second power supply through the second conductive nozzle.
[0011] Preferably, the non-consumable electrode welding torch one and the non-consumable electrode welding torch two form an angle of 30° to 120°.
[0012] Preferably, the distance between the ends of the first filament and the second filament is 3 mm to 10 mm, and the included angle between the first filament and the second filament is 0° to 60°.
[0013] Preferably, the first wire and the axis of the first non-consumable electrode welding gun are at an angle of 30° to 75°, and the second wire and the axis of the second non-consumable electrode welding gun are at an angle of 30° to 75°.
[0014] Preferably, the ultrasonic head is placed on the side of the deposition layer, the distance between the ultrasonic head and the deposition layer is 3 mm to 300 mm, and the angle between the axis of the ultrasonic head and the substrate plane is 0° to 90°.
[0015] Preferably, the ultrasonic head clamping device can adjust the position of the ultrasonic head.
[0016] Preferably, the welding torch clamping mechanism and the substrate are fixed on a three-dimensional processing platform.
[0017] An ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing method, characterized by comprising the following steps:
[0018] (1) Select a suitable material as the substrate, mechanically clean the surface of the substrate to expose the metallic luster, and then clean it with acetone;
[0019] (2) Fix the substrate onto the processing platform, adjust the distance between the non-fusible electrode tip and the upper surface of the substrate to about 3 mm to 10 mm, adjust the horizontal distance between the wire tip and the non-fusible electrode tip to 1 mm to 10 mm, and adjust the distance between the tungsten electrode tip and the upper surface of the substrate to about 3 mm to 15 mm.
[0020] (3) Adjust the position of the ultrasonic head to be 1mm~3mm higher than the substrate and 10mm~200mm away from the center of the upper surface of the substrate. The angle between the ultrasonic head and the plane of the substrate is 0°~90°. The relative position of the ultrasonic head and the non-consumable electrode welding gun remains unchanged.
[0021] (4) The non-consumable electrode welding torch is connected to the negative terminal of the welding power supply, and the wire contact tip is connected to the positive terminal of the power supply;
[0022] (5) Set the arc current to 5 A to 400 A, adjust the wire feeding speed of the wire feeder to 0.2 m / min to 15 m / min, set the argon flow rate to 10 L / min to 25 L / min, and set the substrate moving speed to 30 mm / min to 600 mm / min;
[0023] (6) Turn on the ultrasonic power supply and start the ultrasonic vibration to transmit the ultrasonic vibration to the location where the droplet is about to be deposited;
[0024] (7) Ignite the electric arc, the wire feeding mechanism starts to feed the wire, and after the molten droplet is deposited on the substrate, the substrate starts to move with the worktable and stops at the set position to complete the first layer deposition;
[0025] (8) After the first layer is deposited, the substrate is cooled and returned to the starting position, and the interlayer temperature is controlled to 50 ℃~200 ℃;
[0026] (9) Adjust the height of the welding torch so that the height of the torch is consistent with the thickness of the deposited layer;
[0027] (10) Begin the next layer deposition, repeating (7), (8), (9), and (10);
[0028] (11) After the set deposition size is reached, stop wire feeding, extinguish the arc and stop gas, and turn off the ultrasonic.
[0029] Preferably, the welding power supply mode is selected as DC, pulse, or AC, depending on the wire material used.
[0030] Preferably, the filaments used are of the same type or are of different types.
[0031] Compared with the prior art, the present invention has the following beneficial effects:
[0032] 1. Significantly reduces heat input and heat accumulation in the deposited layer, so that most of the heat of the deposited layer comes from the molten droplets, thereby avoiding overheating of the deposited layer, refining the grains, increasing the equiaxed grain region, improving the anisotropy of the additive part structure, and enhancing its mechanical properties;
[0033] 2. Due to the use of multiple filaments, the deposition rate and productivity of arc additive manufacturing can be increased several times, allowing the advantages of arc additive manufacturing to be further realized.
[0034] 3. Ultrasonic waves acting on the deposited layer not only improve the wetting and spreading of the deposit, but also further refine the grains and improve the anisotropy of the microstructure, thereby further enhancing the mechanical properties.
[0035] 4. Non-contact ultrasound overcomes the disadvantage of contact ultrasound where the ultrasonic effect weakens layer by layer when applied to the back of the substrate.
[0036] 5. This method is not limited by the type of metal material. It can be used not only for ferrous metals such as steel, but also for non-ferrous metals such as aluminum alloys, magnesium alloys, and titanium alloys, as well as high-temperature alloys. It is suitable for a wide range of materials. For aluminum alloys and magnesium alloys, AC (sine wave, square wave, triangular wave, etc.) arcs can be selected. For other materials, DC and pulse forms can be used. That is, the selection can be flexible according to the different wire materials.
[0037] 6. This invention can be used not only for additive manufacturing of single materials, but also for additive manufacturing and development of a variety of new materials, such as gradient materials, bimetallic materials, multimetallic materials, medium-entropy alloys and high-entropy alloys. Attached Figure Description
[0038] Figure 1 This is a schematic diagram of the additive manufacturing apparatus described in this invention;
[0039] Figure 2 This is a schematic diagram of the working position of the ultrasonic probe described in this invention;
[0040] In the diagram: 1-1, Power supply one; 1-2, Power supply two; 2-1, Wire feeder one; 2-2, Wire feeder two; 3-1, Non-consumable electrode welding torch one; 3-2, Non-consumable electrode welding torch two; 4-1, Conductive nozzle one; 4-2, Conductive nozzle two; 5-1, Wire one; 5-2, Wire two; 6, Wire clamping mechanism; 7, Welding torch clamping mechanism; 8, Ultrasonic head clamping mechanism; 9, Ultrasonic system; 10, Ultrasonic generating system; 11, Ultrasonic head; 12, Substrate; 13, Deposition layer; 14, Three-dimensional machining platform. Detailed Implementation
[0041] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0042] Please see Figure 1-2 An ultrasonic-assisted dual-wire consumable electrode-non-consumable electrode arc additive manufacturing device includes: power supply one (1-1), power supply two (1-2), wire feeder one (2-1), wire feeder two (2-2), non-consumable electrode welding torch one (3-1), non-consumable electrode welding torch two (3-2), conductive nozzle one (4-1), conductive nozzle two (4-2), wire one (5-1), wire two (5-2), wire clamping mechanism (6), welding torch clamping mechanism (7), ultrasonic head clamping mechanism (8), and ultrasonic system (9).
[0043] The ultrasound system (9) includes an ultrasound generating system (10) and an ultrasound head (11).
[0044] Non-consumable electrode welding torch one (3-1) and non-consumable electrode welding torch two (3-2) are fixed by welding torch clamping mechanism (7), wire one (5-1) and wire two (5-2) are clamped by wire clamping mechanism (6), and wire clamping mechanism (6) is connected to non-consumable electrode welding torch one (3-1) and non-consumable electrode welding torch two (3-2); ultrasonic head clamping mechanism (8) is rigidly connected to welding torch clamping mechanism (7), and ultrasonic head (11) is fixed by ultrasonic head clamping mechanism (8).
[0045] Among them, non-consumable electrode welding gun one (3-1) is connected to the negative terminal of power supply one (1-1), and non-consumable electrode welding gun two (3-2) is connected to the negative terminal of power supply two (1-2); wire one (5-1) is connected to the positive terminal of power supply one (1-1) through conductive nozzle one (4-1), and wire two (5-2) is connected to the positive terminal of power supply two (1-2) through conductive nozzle two (4-2).
[0046] Among them, the non-consumable electrode welding gun one (3-1) and the non-consumable electrode welding gun two (3-2) form an angle of 30° to 120°.
[0047] The distance between the ends of wire one (5-1) and wire two (5-2) is 3 mm to 10 mm, and the angle between wire one (5-1) and wire two (5-2) is 0° to 60°.
[0048] Among them, the angle between the first wire (5-1) and the axis of the first non-consumable electrode welding gun (3-1) is 30°~75°, and the angle between the second wire (5-2) and the axis of the second non-consumable electrode welding gun (3-2) is 30°~75°.
[0049] The ultrasonic head is placed on the side of the deposition layer (13), the ultrasonic head (11) is 3 mm to 300 mm away from the deposition layer (13), and the angle between the axis of the ultrasonic head (11) and the plane of the substrate (12) is 0° to 90°.
[0050] The ultrasonic head clamping device (8) can adjust the position of the ultrasonic head (11).
[0051] The welding torch clamping mechanism (7) and the substrate (12) are fixed on the three-dimensional processing platform (14).
[0052] An ultrasound-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing method includes the following steps:
[0053] (1) Select a suitable material as the substrate, mechanically clean the surface of the substrate to expose the metallic luster, and then clean it with acetone;
[0054] (2) Fix the substrate onto the processing platform, adjust the distance between the non-fusible electrode tip and the upper surface of the substrate to about 3 mm to 10 mm, adjust the horizontal distance between the wire tip and the non-fusible electrode tip to 1 mm to 10 mm, and adjust the distance between the tungsten electrode tip and the upper surface of the substrate to about 3 mm to 15 mm.
[0055] (3) Adjust the position of the ultrasonic head to be 1 mm to 3 mm above the upper surface of the substrate and 10 mm to 200 mm away from the center of the upper surface of the substrate. The angle between the ultrasonic head and the plane of the substrate is 0° to 90°. The relative position of the ultrasonic head and the non-consumable electrode welding gun remains unchanged.
[0056] (4) The non-consumable electrode welding torch is connected to the negative terminal of the welding power supply, and the wire contact tip is connected to the positive terminal of the power supply;
[0057] (5) Set the arc current to 5 A to 400 A, adjust the wire feeding speed of the wire feeder to 0.2 m / min to 15 m / min, set the argon flow rate to 10 L / min to 25 L / min, and set the substrate moving speed to 30 mm / min to 600 mm / min;
[0058] (6) Turn on the ultrasonic power supply and start the ultrasonic vibration to transmit the ultrasonic vibration to the location where the droplet is about to be deposited;
[0059] (7) Ignite the electric arc, the wire feeding mechanism starts to feed the wire, and after the molten droplet is deposited on the substrate, the substrate starts to move with the worktable and stops at the set position to complete the first layer deposition;
[0060] (8) After the first layer is deposited, the substrate is cooled and returned to the starting position, and the interlayer temperature is controlled to 50℃~200℃;
[0061] (9) Adjust the height of the welding torch so that the height of the torch is consistent with the thickness of the deposited layer;
[0062] (10) Begin the next layer deposition, repeating (7), (8), (9), and (10);
[0063] (11) After the set deposition size is reached, stop wire feeding, extinguish the arc and stop gas, and turn off the ultrasonic.
[0064] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.
[0065] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. An ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus and method, characterized in that: Includes power supply 1 (1-1), power supply 2 (1-2), wire feeder 1 (2-1), wire feeder 2 (2-2), non-consumable electrode welding torch 1 (3-1), non-consumable electrode welding torch 2 (3-2), conductive nozzle 1 (4-1), conductive nozzle 2 (4-2), wire 1 (5-1), wire 2 (5-2), wire clamping mechanism (6), welding torch clamping mechanism (7), ultrasonic head clamping mechanism (8), and ultrasonic system (9); The ultrasound system (9) includes an ultrasound generating system (10) and an ultrasound head (11). The non-consumable electrode welding torch one (3-1) and the non-consumable electrode welding torch two (3-2) are fixed by the welding torch clamping mechanism (7). The wire one (5-1) and the wire two (5-2) are clamped by the wire clamping mechanism (6). The wire clamping mechanism (6) is connected to the non-consumable electrode welding torch one (3-1) and the non-consumable electrode welding torch two (3-2). The ultrasonic head clamping mechanism (8) is rigidly connected to the welding torch clamping mechanism (7). The ultrasonic head (11) is fixed by the ultrasonic head clamping mechanism (8).
2. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus according to claim 1, characterized in that: The first non-consumable electrode welding torch (3-1) is connected to the negative terminal of the first power supply (1-1), and the second non-consumable electrode welding torch (3-2) is connected to the negative terminal of the second power supply (1-2); the first wire (5-1) is connected to the positive terminal of the first power supply (1-1) through the first conductive nozzle (4-1), and the second wire (5-2) is connected to the positive terminal of the second power supply (1-2) through the second conductive nozzle (4-2).
3. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus according to claims 1-2, characterized in that: The non-consumable electrode welding gun one (3-1) and the non-consumable electrode welding gun two (3-2) form an angle of 30° to 120°.
4. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus according to claims 1-3, characterized in that: The distance between the ends of the first filament (5-1) and the second filament (5-2) is 3 mm to 10 mm, and the angle between the first filament (5-1) and the second filament (5-2) is 0° to 60°.
5. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus according to claims 1-4, characterized in that: The angle between the first wire (5-1) and the axis of the first non-consumable electrode welding gun (3-1) is 30° to 75°, and the angle between the second wire (5-2) and the axis of the second non-consumable electrode welding gun (3-2) is 30° to 75°.
6. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus according to claims 1-5, characterized in that: The ultrasonic head is placed on the side of the deposition layer (13), the ultrasonic head (11) is 3 mm to 300 mm away from the deposition layer (13), and the angle between the axis of the ultrasonic head (11) and the plane of the substrate (12) is 0° to 90°.
7. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing apparatus according to claims 1-6, characterized in that: The welding torch clamping mechanism (7) and the substrate (12) are fixed on the three-dimensional processing platform (14), and the ultrasonic head clamping device (8) can adjust the position of the ultrasonic head (11).
8. A method for ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing, characterized in that... Includes the following steps: (1) Select a suitable material as the substrate, mechanically clean the surface of the substrate to expose the metallic luster, and then clean it with acetone; (2) Fix the substrate onto the processing platform, adjust the distance between the non-fusible electrode tip and the upper surface of the substrate to about 3 mm to 10 mm, adjust the horizontal distance between the wire tip and the non-fusible electrode tip to 1 mm to 10 mm, and adjust the distance between the tungsten electrode tip and the upper surface of the substrate to about 3 mm to 15 mm. (3) Adjust the position of the ultrasonic head to be 1 mm to 3 mm above the upper surface of the substrate and 10 mm to 200 mm away from the center of the upper surface of the substrate. The angle between the ultrasonic head and the plane of the substrate is 0° to 90°. The relative position of the ultrasonic head and the non-consumable electrode welding gun remains unchanged. (4) The non-consumable electrode welding torch is connected to the negative terminal of the welding power supply, and the wire is connected to the positive terminal of the power supply through the conductive tip; (5) Set the arc current to 5 A to 400 A, match and adjust the wire feeding speed of the wire feeder to 0.2 m / min to 15 m / min, set the argon flow rate to 10 L / min to 25 L / min, and set the substrate moving speed to 30 mm / min to 600 mm / min; (6) Turn on the ultrasonic power supply and start the ultrasonic vibration to transmit the ultrasonic vibration to the location where the droplet is about to be deposited; (7) Ignite the electric arc, the wire feeding mechanism starts to feed the wire, and after the molten droplet is deposited on the substrate, the substrate starts to move with the worktable and stops at the set position to complete the first layer deposition; (8) After the first layer is deposited, the substrate is cooled and returned to the starting position, and the interlayer temperature is controlled to 50℃~200℃; (9) Adjust the height of the welding torch so that the rising height is consistent with the thickness of the single-layer deposition layer; (10) Begin the next layer deposition, repeating (7), (8), (9), and (10); (11) After the set deposition size is reached, stop wire feeding, extinguish the arc and stop gas, and turn off the ultrasonic.
9. The ultrasonic-assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing method according to claim 8, characterized in that: Select the welding power mode as DC, pulse, or AC, depending on the wire material used.
10. A method for ultrasonically assisted dual-wire fused electrode-non-fused electrode arc additive manufacturing according to claims 8-9, characterized in that: The wire used can be of the same type or of different types.