Method and device for additive manufacturing with heterogeneous metals and combined casting and rolling in situ

Abstract

To improve the performance of casting and rolling.SOLUTION: A method of additive manufacturing with foreign metals and combined casting and rolling in situ according to one embodiment includes preheating a solid metal, additive manufacturing with foreign filaments being melted, combined casting and rolling in situ, and building a form layer by layer. The additive manufacturing system and the casting and rolling system are respectively arranged on two sides of the platform, the additive manufacturing system transports multiple heterogeneous filaments, and the heat source melts the filaments into liquid and melts the filaments into solid metal for coating, so that the heterogeneous metal interface can be mixed and melted according to a target proportion during connection.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to the technical field of combining metal casting and rolling, and in particular to a method and device for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ. [Background technology]

[0002] Filament melting additive manufacturing is an additive manufacturing technology that uses an arc, laser, or other heat source to heat and melt synchronously added metal filaments, which are then deposited layer by layer along a predetermined path while melting to form a three-dimensional entity. This technology has advantages such as a fast formation speed, high material utilization rate, a short overall production cycle, and suitability for large metal structures. Furthermore, the formed product has uniform composition and high density, providing excellent performance and prospects for application in fields such as biology and medical projects, energy infrastructure construction, micro- and nano-related manufacturing, and aviation and space. However, filament melting additive manufacturing also has problems such as a large heat input and low formation accuracy.

[0003] Patent Document 1 discloses a technology for filament melting using an arc to perform additive manufacturing. This method applies a stable and constant transverse magnetic field in situ, adjusting the strength of the transverse magnetic field depending on the magnetic strength of the product to be formed. This improves the formation of weld seams, reduces defects caused by internal gas holes, refines internal particles, and suppresses element segregation. Patent Document 2 discloses an in-situ surface treatment device and method for filament melting using an electron beam to perform additive manufacturing. This method utilizes in-situ electron beam treatment technology, positioning the forming platform for melting and depositing using an electron beam using optical and distance measurement devices, and melts the surface of the part using a surface treatment electron beam gun, removing unmelted areas and microcracks that occur during deposition. The above-mentioned documents each deal with the process of solidifying metals by methods such as microalloying, mechanical vibration, electromagnetic field, and laser, but do not deal with latent defects that have already formed, so their application is limited to manufacturing large and complex products.

[0004] Currently, interlayer cold rolling processes can refine grain and reduce residual stress, but require relatively large rolling forces and equipment rigidity, limiting the production of structures with weak rigidity or special shapes. Cold forging processes can also achieve dense deformation of metals, refine grains, and reduce porosity, but the cold forging forces are relatively low, so only a few hammer strikes are required to achieve significant grain refinement. Forging processes synchronous with hot forging can more easily achieve significant grain refinement by changing the internal stress of metals from tensile to compressive, but currently, these processes are not typically adjusted or controlled for anything other than single-element materials. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Chinese Patent Application Publication No. 113798632 [Patent Document 2] Chinese Patent Application Publication No. 115740490 Summary of the Invention [Problem to be solved by the invention]

[0006] As mentioned above, methods such as microalloying, mechanical vibration, electromagnetic fields, and lasers interfere with the metal solidification process and are therefore not effective in treating defects that have already formed. Currently, interlayer cold rolling, cold forging, and hot synchronous forging processes are typically adjusted and controlled based on the performance of the single-element material itself. Therefore, when additive manufacturing dissimilar metals, it is desirable to quickly solve the problem of adjusting and controlling the performance of the dissimilar metal composite interface and the single-element metallurgical structure in situ using a technology that focuses on the composite interface and controls it. [Means for solving the problem]

[0007] To address the shortcomings of the prior art, the present invention provides a method and device for in-situ combined casting and rolling using dissimilar metals for additive manufacturing. Multiple filament feed modules in the additive manufacturing system transport multiple dissimilar filaments at different speeds, either independently or synchronously. A heat source melts the filaments into liquid metal, which is then melted and coated onto a solid metal, achieving the desired proportion of mixing and melting when connecting the interfaces of the dissimilar metals. Casting and rolling roller components in the casting and rolling system combine casting and rolling of the liquid metal melted and coated above the solid metal, forming strong local stresses, achieving metallurgical bonding at spatial interfaces of homogeneous or heterogeneous materials, reducing residual stress, and improving the performance of the casting and rolling process.

[0008] To achieve the above object, the present invention adopts the following technical solutions.

[0009] The present invention provides a method for additive manufacturing of dissimilar metals and combining in situ casting and rolling, comprising the steps of: Step S1 preheats the solid metal by turning on the temperature control module and detecting the preheat temperature of the solid metal in real time using the temperature measurement sensor so that the preheat temperature of the solid metal reaches a temperature T1. In step S2, additive manufacturing is performed using the molten heterogeneous filament. In this step, when the preheating temperature of the solid metal reaches temperature T1, the first industrial robot coordinates with multiple filament feeding modules to transport the solid coated metal filament, and the solid coated metal filament is melted into liquid coated metal droplets by the action of a heat source, thereby melting and coating the solid metal surface to form a melting pool region. During the melting and coating, the temperature of the solid metal is adjusted and controlled so that the real-time temperature of the solid metal reaches temperature T1. Step S3 combines casting and rolling in situ. In this step, a coolant is introduced into the casting and rolling roller, and when the liquid metal and the solid metal form a solid-liquid interface in the melt pool area, the casting and rolling roller parts combine casting and rolling in situ with the solid-liquid interface, and a second industrial robot is interlocked to form a molten metal layer with a micro-structured surface on the solid metal. Step S4 is a layer-by-layer construction step in which steps S2 and S3 are repeated according to a predetermined path to continuously perform additive manufacturing on the molten and coated metal layer, forming a three-dimensional object by depositing each layer multiple times, and finally obtaining the heterogeneous metal composite material formed by combining additive manufacturing with casting and rolling. Before depositing each layer multiple times and during the molten and coated process, a temperature sensor is used to detect the real-time temperature T2 of the molten and coated metal layer, and the real-time temperature T2 of the molten and coated metal layer is adjusted and controlled so that the real-time temperature T2 is equal to the temperature T1.

[0010] Preferably, in step S4, when T2 < T1, until T2 becomes equal to T1, the temperature control module is used to raise the temperature of the molten and coated metal layer, and then steps S2 and S3 are repeated to perform layered forming and the composite of casting and rolling. On the other hand, when T2 > T1, until T2 becomes equal to T1, the temperature control module is used to cool the molten and coated metal layer, and then steps S2 and S3 are repeated to perform layered forming and the composite of casting and rolling.

[0011] Preferably, in step S2, the first industrial robot interlocks a plurality of filament feeding modules, transports homogeneous or heterogeneous solid coated metal filaments according to the performance of the target single element in the molten and coated metal layer, and adjusts the transport speeds of various solid coated metal filaments, so as to realize mixing and melting the solid coated metal filaments according to the target ratio.

[0012] Preferably, in step S3, the casting and rolling roller sleeve in the casting and rolling roller component has an outer diameter of the first side shape rectifying part and the second side shape rectifying part larger than the outer diameter of the central form installation part. The first side shape rectifying part and the second side shape rectifying part press inward while contacting both sides of the melting pool area. The central form installation part in the casting and rolling roller sleeve contacts the liquid metal and performs in-situ composite casting and rolling for the solid-liquid state. After undergoing cooling and deformation by rolling, the liquid metal solidifies into solid metal.

[0013] Preferably, in step S2, when melting the solid coated metal filament into droplets of liquid coated metal by a heat source, the droplets of liquid coated metal perform a falling motion due to gravity. When the droplets of liquid coated metal perform a falling motion in a magnetic field by a magnetic field generating device, they receive a Lorentz force and the motion trajectory becomes deflected. By changing the magnitude or direction of the current, or changing the position of the coil, the direction and intensity of the magnetic field can be changed, so that the droplets of liquid coated metal can move towards the casting and rolling roller component and enter the area of the melting pool.

[0014] Preferably, in step S3, the casting / rolling roller components are linked to vibrate at high frequency by a vibration field means, and when combining in-situ casting and rolling of the solid and liquid, the vibration field energy is conducted to the vicinity of the solidification point within the area where in-situ casting and rolling of the solid and liquid is carried out, or the casting / rolling roller components and the solid metal are respectively conducted to the positive and negative poles of a pulse power source to form a closed circuit, and when a pulse electric field is applied, a pulse current is applied to the vicinity of the solidification point within the area where in-situ casting and rolling of the solid and liquid is carried out.

[0015] According to a second aspect of the present invention, there is provided a manufacturing system including a workbench, and an additive manufacturing system and a casting and rolling system installed on both sides of the workbench, the additive manufacturing system including a first industrial robot, a heat source, a plurality of filament feeding modules, a temperature control module and an adjustment device, the adjustment device being installed at an end of the first industrial robot, the heat source being installed at a first end of the adjustment device, the plurality of filament feeding modules being connected to a second end of the adjustment device, and the temperature control module being attached to one side of the plurality of filament feeding modules, the casting and rolling system including casting and rolling roller components, a second industrial robot and a connection adjustment device, the connection adjustment device being installed at an end of the second industrial robot, and the casting and rolling roller components being connected to the connection adjustment device. and a casting / rolling roller part attached to the tip of the casting / rolling roller shaft, the casting / rolling roller part including an entrance sleeve, a casting / rolling roller shaft, a casting / rolling roller sleeve, and an exit sleeve, the entrance sleeve being connected to a first end of the casting / rolling roller shaft, the casting / rolling roller sleeve being located at a central position on the casting / rolling roller shaft, and the exit sleeve being connected to a second end of the casting / rolling roller shaft, the casting / rolling roller sleeve including a first side shape review section, a central form setting section, and a second side shape review section which are sequentially arranged along the axial direction of the casting / rolling roller sleeve, the central form setting section having a spatial form setting on its outer surface, thereby providing a device for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ.

[0016] Preferably, the system further includes an energy field system, the energy field system including one or more of electromagnetic field means, vibration field means, and pulse electric field means, the electromagnetic field means being installed near the heat source and the multiple filament feeding modules, the liquid coating metal being subjected to Lorentz force when moving in the electromagnetic field, and being able to change its moving trajectory, the vibration field means being installed between the second industrial robot and the connection adjustment device in the casting and rolling system, and being linked to vibrate the casting and rolling roller parts at high frequency, the pulse electric field means being conducted to the casting and rolling roller parts and the solid metal via the positive pole and negative pole of the pulse power supply, respectively, to form a closed circuit, and the pulse electric field acts in situ on the solid-liquid at the solidification point in the casting and rolling area.

[0017] Preferably, the plurality of filament feeding modules have a plurality of filament inlets thereon for transporting homogeneous or heterogeneous solid coated metal filaments, and the temperature control module has a temperature measurement sensor mounted therein.

[0018] Preferably, the casting / rolling roller shaft includes an inlet section, a circulation section, and an outlet section, the inlet section having an inlet hole at the center, the outlet section having an outlet annular groove, the circulation section having a plurality of input through holes and return through holes, the input through holes and the inlet holes communicating with each other, the return through holes communicating with the outlet annular groove, and the input through holes and the return through holes alternately arranged sequentially and uniformly along the circumferential direction of the circulation section. [Effects of the Invention]

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] (1) The device of the present invention, which performs additive manufacturing using dissimilar metals and combines casting and rolling in situ, has a temperature measurement sensor installed inside a temperature control module. The temperature control module preheats the solid metal, and at the same time, the temperature measurement sensor detects the preheating temperature of the solid metal in real time. This controls the temperature gradient at the solid-liquid interface in accordance with the input energy of the heat source, thereby controlling the size of the melting pool in additive manufacturing, adjusting the degree of supercooling of the liquid metal, and achieving control over the solidification structure in additive manufacturing.

[0021] (2) The in-situ casting and rolling method for additive manufacturing of dissimilar metals according to the present invention is designed to match the target single-element performance. Multiple filament feed modules transport multiple dissimilar filaments independently or synchronously at different speeds, achieving the desired proportion of mixing and melting when connecting the dissimilar metal interfaces. In combination with the casting and rolling system, the liquid metal is deeply supercooled in situ, rapidly solidified, and undergoes non-uniform plastic deformation, resulting in a solid metal entity with a gradient microscopic structure and excellent performance compared to single-element metals. This also reduces the load and achieves a gradient connection between dissimilar metals.

[0022] (3) In the device for additive manufacturing using dissimilar metals and combining casting and rolling in situ according to the present invention, the casting and rolling roller sleeve in the casting and rolling system has a spatial configuration, such as a ripple or arc shape, on the outer surface of the central configuration installation section. The spatial configuration can improve the surface tension when contacting the liquid metal, and the previously obtained surface micro-structure can improve the wettability of the current liquid metal and form better contact at the solid-liquid interface, promoting the subsequent spreading of the metal and improving the effectiveness of melting and coating of the liquid metal. At the same time, during the process of combining casting and rolling, strong local stress is generated, which promotes interface fracture or indentation due to non-uniform plastic deformation, and can heal internal defects at a relatively low deformation temperature and with a relatively small deformation amount, thereby achieving metallurgical bonding at spatial interfaces of homogeneous or heterogeneous materials and reducing residual stress. The casting and rolling rollers use the first edge shape revision section and the second edge shape revision section to revise both sides of the metal body, making the contours between each layer more orderly, and thus improving the forming quality during each melting and coating.

[0023] (4) In the in-situ casting and rolling method for additive manufacturing using dissimilar metals, the central morphology setting section of the casting and rolling roller sleeve generates non-uniform plastic deformation consistent with the spatial morphology setting during the combined casting and rolling process, generating temperature, flow, deformation, and microstructure fields that change over time. This is because, unlike conventional additive manufacturing using filament melting, which relies on thermal and mass conduction at the solid-liquid interface, the method changes the thermal and mass conduction rules and the metal solidification process, thereby suppressing segregation, healing microcracks, and refining grains. Furthermore, compared to the slow, gradual cooling process using air in conventional additive manufacturing, the rapid cooling and rolling deformation performed by the casting and rolling system, as well as the formation at different temperatures in a short period of time, avoids the generation of large amounts of artifacts at the interface, improves the performance of the single-element metal, enhances the bonding strength at the interface, and increases molding efficiency.

[0024] (5) In the method for in-situ casting and rolling using additive manufacturing with dissimilar metals according to the present invention, in step S3, when a heat source is used to melt a solid coated metal filament into a liquid coated metal droplet, the liquid coated metal droplet moves downward due to gravity. When an external magnetic field is applied, the Lorentz force causes a deflection in the trajectory of the liquid coated metal droplet as it moves downward through the magnetic field. By changing the direction and strength of the magnetic field, the liquid coated metal droplet moves toward the casting / rolling roller part and enters a stable melt pool region in the in-situ solid-liquid casting and rolling region. This improves the flowability of the liquid coated metal located near its freezing point within the stable melt pool region. The liquid coated metal becomes a solid coated metal after undergoing rapid cooling and rolling deformation, thereby realizing in-situ solid-liquid casting and rolling.

[0025] (6) In the method of the present invention for additive manufacturing using dissimilar metals and combining casting and rolling in situ, in step S4, the vibration field means is used to link the casting and rolling roller components to vibrate at high frequency, and when combining casting and rolling in situ in the solid-liquid state, the vibration field energy is transmitted to the vicinity of the solidification point within the region where casting and rolling in situ in the solid-liquid state is performed, thereby destroying the solidified dendrites of the liquid coating metal and reducing the particle size of the solid coating metal, improving the performance of the single-element metal and increasing the bonding strength at the composite interface.

[0026] (7) In the method of the present invention for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ, in step S4, the casting / rolling roller sleeve and the solid metal are connected to the positive and negative poles of a pulsed power source, respectively, to form a closed circuit, and a pulsed electric field is applied. The pulsed current acts on the solid-liquid in situ near the solidification point within the casting and rolling region, improving the state of dendrite formation before solidification and reducing particle size, changing the surface tension and wettability in the liquid coating metal, improving the performance of the structure in the solid coating metal, and promoting atomic diffusion at the composite interface, thereby forming a strong metallurgical bond. [Brief explanation of the drawings]

[0027] [Figure 1] FIG. 1 is a schematic diagram showing a method for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ according to the present invention. [Figure 2] 1 is a flowchart illustrating a method for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ according to the present invention. [Figure 3] 1 is a schematic diagram showing the overall configuration of a device for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ according to the present invention. [Figure 4] FIG. 1 is a diagram showing a configuration in which an additive manufacturing system and a casting / rolling system according to the present invention are locally enlarged. [Figure 5] 1 is a schematic diagram showing the configuration of an additive manufacturing system according to the present invention. [Figure 6] 1 is a schematic diagram showing the configuration of a casting and rolling system according to the present invention. [Figure 7] 1 is a schematic diagram showing the configuration of parts of a casting / rolling roller according to the present invention. FIG. [Figure 8] 1 is a cross-sectional view showing a part of a casting and rolling roller according to the present invention. [Figure 9] 1 is a schematic diagram showing the configuration of a casting / rolling roller shaft according to the present invention. FIG. [Figure 10] 1 is a cross-sectional view showing a casting / rolling roller shaft according to the present invention. [Figure 11] 1 is a schematic diagram showing the configuration of a casting / rolling roller sleeve according to the present invention. FIG. [Figure 12] 1 is a schematic diagram showing the operation of an in situ combined casting and rolling device in a multi-energy field during additive manufacturing with dissimilar metals according to the present invention. [Figure 13] FIG. 1 is a schematic diagram showing the application of an electromagnetic field during in situ casting and rolling combined in the present invention. [Figure 14]FIG. 1 is a schematic diagram illustrating the application of oscillatory field energy during in situ casting and rolling according to the present invention. [Figure 15] FIG. 1 is a schematic diagram illustrating the application of a pulsed electric field during in situ casting and rolling according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0028] The technical contents, objects to be achieved, and effects of the present invention will be described in detail below with reference to the drawings.

[0029] As shown in Fig. 3, the device for performing additive manufacturing using dissimilar metals and combining in situ casting and rolling according to the present invention includes a work table 1, an additive manufacturing system 2, and a casting and rolling system 3, which are installed on either side of the work table 1, respectively. The additive manufacturing system 2 is for melting a filament to perform additive manufacturing, and the casting and rolling system 3 is for combining casting and rolling of a liquid metal located above a solid metal 4. As shown in Fig. 12, the additive manufacturing system 2 melts the molten liquid metal above the solid metal 4 to cover it, and the casting and rolling system 3 then combines casting and rolling.

[0030] 5 , the additive manufacturing system 2 includes a first industrial robot 201, a heat source 202, multiple filament feeding modules 203, a temperature control module 204, and an adjustment device 205. The adjustment device 205 is installed at the end of the first industrial robot 201, and the heat source 202 is installed at a first end of the adjustment device 205. The heat source 202 is for melting the filament, and the multiple filament feeding modules 203 are connected to a second end of the adjustment device 205. The multiple filament feeding modules 203 have multiple filament inlets on the upper side, which are used to transport provided homogeneous or heterogeneous solid-coated metal filaments. The filaments can be supplied independently or synchronously at different speeds to achieve gradient mixing and melting in the process of connecting the heterogeneous metal interfaces. The temperature control module 204 is attached to the side of the multiple filament feeding modules 203. The temperature control module 204 has a temperature measurement sensor attached thereto and controls the temperature difference between the solid metal 4 and the metal droplets melted by the filament based on the energy input from the heat source 202, so that the solid metal 4 is maintained at the initial preheating temperature T1. The temperature control module 204 has the functions of preheating and cooling, and can heat or cool the solid metal 4 according to the actual temperature.

[0031] 6, the casting and rolling system 3 includes a casting and rolling roller part 301, a second industrial robot 302, and a connection and adjustment device 303, and the connection and adjustment device 303 is installed at the end of the second industrial robot 302. The connection and adjustment device 303 is for connecting the casting and rolling roller part 301 and the second industrial robot 302, and the second industrial robot 302 controls the casting and rolling roller part 301 to move in cooperation with the additive manufacturing system 2, and the casting and rolling roller part 301 is attached to the tip of the connection and adjustment device 303.

[0032] 7 and 8, the casting / rolling roller part 301 includes an inlet pipe fitting 3011, an inlet sleeve 3012, a bearing 3013, a casting / rolling roller shaft 3014, a bearing seat 3015, a casting / rolling roller sleeve 3016, an outlet sleeve 3017, and an outlet pipe fitting 3018. The inlet pipe fitting 3011 is threadedly connected to the inlet sleeve 3012, and the inlet sleeve 3012 is connected to a first end of the casting / rolling roller shaft 3014. The bearing 3013 is mounted on a first end of the bearing seat 3015, and the second end of the bearing seat 3015 is connected to the connection adjustment device 303. Both ends of the casting / rolling roller shaft 3014 pass through the inner race of the bearing 3013. The casting / rolling roller sleeve 3016 is mounted around the center of the casting / rolling roller shaft 3014. The inlet sleeve 3017 is connected to the second end of the casting / rolling roller shaft 3014. The outlet pipe fitting 3018 is threadedly connected to the outlet sleeve 3017.

[0033] 9 and 10, the casting / rolling roller shaft 3014 includes an inlet section 30141, a circulation section 30142, and an outlet section 30143, which are arranged in this order along the axial direction of the casting / rolling roller shaft 3014. The inlet section 30141 has an inlet hole 301411 at its center, the outlet section 30143 has an outlet annular groove 301431, and the circulation section 30142 has a plurality of input through holes 301421 and return through holes 301422 along the axial centerline of the casting / rolling roller shaft 3014. The input through-holes 301421 and the return through-holes 301422 are uniformly arranged in a sequential manner along the circumferential direction of the circulation section 30142. The input through-holes 301421 are connected to the inlet holes 301411, and the return through-holes 301422 are connected to the outlet annular groove 301431. The refrigerant flows from the inlet pipe fitting 3011 into the inlet hole 301411 of the inlet section 30141, passes along the input through-holes 301421, and enters the gap between the circulation section 30142 and the casting / rolling roller sleeve 3016. As the casting / rolling roller shaft 3014 rotates, the refrigerant flows from the return through-holes 301422 to the outlet annular groove 301431 of the outlet section 30143, and finally flows out from the outlet pipe fitting 3018.

[0034] As shown in FIG. 11 , the casting-rolling roller sleeve 3016 includes a first side shape review portion 30161, a central shape setting portion 30162, and a second side shape review portion 30163, which are arranged sequentially along the axial direction of the casting-rolling roller sleeve 3016. The first side shape review portion 30161 and the second side shape review portion 30163 have diameters larger than the diameter of the central shape setting portion 30162. The first side shape review portion 30161 and the second side shape review portion 30163 have the same configuration but are provided with conicity at both ends. This allows the shapes of the sides located on both sides of the metal entity to be additively manufactured to be reviewed, making the contours between each layer more regular and ultimately improving the manufacturing quality when melting and coating are performed one after another. The central feature mounting portion 30162 has a spatial feature on its outer surface, and the curve of the spatial feature may be a smooth curve or one or more of a sine, cosine, arc, triangle, ripple, or striated curve. When the central feature mounting portion 30162 comes into contact with the liquid metal, a strong local stress is generated, which can achieve a strong metallurgical bond at the spatial interface between the solid metal 4 and the liquid metal.

[0035] In a specific embodiment, an energy field system may be further installed. The energy field system may include one or more of an electromagnetic field means, a vibration field means, and a pulsed electric field means. The energy field system can finely adjust and control the structure function during additive manufacturing of molten filaments for heterogeneous metal layered composite materials. The electromagnetic field means is installed near the heat source and multiple filament feeding modules, and the Lorentz force can change the movement trajectory of the liquid coating metal as it moves through the electromagnetic field. The vibration field means is installed between the second industrial robot and the connection adjustment device in the casting and rolling system and can be linked to vibrate the casting and rolling roller components at high frequency. The pulsed electric field means is conductive to the casting and rolling roller components and the solid metal via the positive and negative poles of a pulsed power supply, respectively, to form a closed circuit, and the pulsed electric field is applied directly to the solidification point in the area where the solid-liquid is cast and rolled in situ.

[0036] Specifically, the present invention provides a method for additive manufacturing using dissimilar metals and combining in-situ casting and rolling, as shown in Figures 1 and 2, which includes the following steps:

[0037] In step S1, the solid metal is preheated. The additive manufacturing system 2 and the casting and rolling system 3 are installed on opposite sides of the worktable 1. The temperature control module 204 is turned on to preheat the solid metal 4, and the preheating temperature of the solid metal 4 is detected in real time using a non-contact radiation temperature measurement sensor. The temperature of the solid metal 4 is controlled to be maintained at temperature T1 according to the input energy from the heat source 202 so that the preheating temperature of the solid metal 4 becomes temperature T1. Temperature T1 is determined by the melting temperature of the filament and can be controlled by adjusting the degree of supercooling of the solid metal 4 to avoid an excessively large temperature difference between the solid metal and the molten filament droplets.

[0038] Step S2 involves additive manufacturing using the molten heterogeneous filaments. After preheating the solid metal 4 to a predetermined temperature T1, the first industrial robot 201 coordinates multiple filament feeding modules 203 to independently or synchronously transport homogeneous or heterogeneous solid-coated metal filaments according to the target single-element performance. The solid-coated metal filaments are melted into liquid coating metal droplets by a heat source 202, which are melted and coated onto the surface of the solid metal 4, forming a stable melt pool region. During melting and coating, the temperature of the solid metal is adjusted and controlled to maintain the real-time temperature of the solid metal at temperature T1. When transporting the solid-coated metal filaments, the speed at which various types of solid-coated metal filaments are transported is adjusted to achieve a mixed melting of the heterogeneous solid-coated metal filaments according to the target proportion. The target single-element performance refers to the performance of the target single-element metal of the molten and coated metal layer. The single-element metal may be a homogeneous metal or a heterogeneous metal. By adjusting the speed at which the foreign solid coating metal filaments are transported, the proportions at which the foreign liquid coating metal droplets mix and melt can be achieved.

[0039] When a heat source melts a solid coated metal filament into liquid coated metal droplets, the liquid coated metal droplets move downward due to gravity, and when an external magnetic field generator is used to cause the liquid coated metal droplets to move downward in a magnetic field, the Lorentz force deflects the trajectory of the liquid coated metal droplets. By changing the magnitude and direction of the current or by changing the position of the coil, the direction and strength of the magnetic field can be changed, and the liquid coated metal droplets will move toward the casting and rolling roller parts and enter the melting pool region in the in-situ solid-liquid casting and rolling area.

[0040] Step S3 combines casting and rolling in situ. When the liquid metal and solid metal 4 are at the solid-liquid interface within the stable melt pool region, a coolant is introduced through the inlet pipe joint 3011, and the second industrial robot 302 in the casting and rolling system 3 operates the casting and rolling roller component 301 to combine casting and rolling in situ at the solid-liquid interface. The first side shape revising unit 30161 and the second side shape revising unit 30163 of the casting and rolling roller sleeve 3016 apply inward pressure to both sides of the melt pool region, causing the central shape setting unit 30162 to come into contact with the liquid metal, thereby combining casting and rolling in situ at the solid-liquid interface. After rapid cooling and rolling deformation, the liquid metal solidifies into solid metal 4. At the same time, the spatial configuration of the central configuration setting portion 30162 generates strong local stress, changes the stress-induced elasticity of the single element metal, increases the stress-induced elasticity strength at the composite interface, and forms a molten metal coating layer with a surface micro-configuration on the solid metal. In this embodiment, the casting / rolling roller part 301 is a micro-casting / rolling roller part, and thus combines micro-casting and rolling in situ between solid and liquid.

[0041] In step S3, the vibration field means is interlocked so that the casting / rolling roller component vibrates at a high frequency. The vibration field energy is transmitted in situ to the vicinity of the internal freezing point in the region where casting and rolling are combined in situ for the solid-liquid state. Alternatively, the casting / rolling roller component and the solid metal are respectively connected to the positive and negative electrodes of the pulse power supply to form a closed circuit. When a pulse electric field is applied, a pulse current acts on the vicinity of the internal freezing point in the region where casting and rolling are combined in situ for the solid-liquid state.

[0042] Step S4 constructs the form layer by layer. The additive manufacturing system repeats steps S2 and S3 according to a predetermined path, continuously performs additive manufacturing above the molten / clad metal layer, and forms a three-dimensional entity by depositing multiple times layer by layer. By combining additive manufacturing and casting / rolling, the finally formed heterogeneous metal composite material is obtained. When depositing layer by layer for each of the multiple times, and when performing melting / cladding, the real-time temperature T2 of the molten / clad metal layer is detected by a temperature measurement sensor, and the real-time temperature T2 of the molten / clad metal layer is adjusted and controlled so that the real-time temperature T2 of the molten / clad metal layer is equal to the temperature T1. The predetermined path is a set deposition path, and generally, it is in the form of depositing layer by layer.

[0043] In step S4, when T2 < T1, the temperature control module causes the molten / clad metal layer to heat up until T2 = T1, and then steps S2 and S3 are repeated to perform additive manufacturing and the combination of casting and rolling.

[0044] When T2 > T1, when T2 > T1, until T2 becomes equal to T1, the temperature control module causes the molten / clad metal layer to cool down, and then steps S2 and S3 are repeated to perform additive manufacturing and the combination of casting and rolling.

[0045] As shown in FIG. 13 , electromagnetic field means are installed near the heat source and the multiple filament feed modules. In step S2, the heat source 202 melts the solid coated metal filament into liquid coated metal droplets. The liquid coated metal droplets then move downward due to gravity G. An external magnetic field is applied, and the liquid coated metal droplets moving downward in the magnetic field are deflected by the Lorentz force FB. By changing the direction and strength of the magnetic field, the liquid coated metal droplets move toward the casting / rolling roller assembly 301, enter the stable melt pool region in the in-situ solid-liquid casting and rolling region, and improve the flowability of the liquid coated metal 5 located near the internal solidification point 100 in the stable melt pool region. The liquid coated metal 5 then undergoes rapid cooling and rolling deformation to become the solid coated metal 6, thereby achieving the in-situ combined casting and rolling of the solid-liquid.

[0046] As shown in Figure 14, a vibration field means is installed between the second industrial robot and the connection adjustment device in the casting and rolling system, and the casting and rolling roller components are connected to vibrate at a high frequency. In step S3, the vibration field means connects the casting and rolling roller components 301 to vibrate at a high frequency f. During the in-situ solid-liquid casting and rolling combination, the vibration field energy is transmitted to the vicinity of the internal solidification point 100 in the in-situ solid-liquid casting and rolling region, thereby destroying the solidified dendrites of the liquid coating metal 5, refining the particle size of the solid coating metal 6, improving the performance of the single-element metal, and increasing the bonding strength at the composite interface.

[0047] As shown in Figure 15, a pulsed electric field is installed, and a closed circuit is formed by connecting the casting / rolling roller part 301 and the solid metal 4 to the positive and negative poles of a pulsed power supply, respectively. In step S3, a closed circuit is formed by connecting the casting / rolling roller part 301 and the solid metal 4 to the positive and negative poles of the pulsed power supply, respectively, and insulating the remaining parts. When a pulsed electric field is applied, a pulsed current acts near the internal solidification point 100 in the in-situ solid-liquid casting and rolling region, improving the growth of dendrites and refining the grain size until solidification, changing the surface tension and wettability of the liquid coating metal 5, improving the microstructure of the solid coating metal 6, and promoting atomic diffusion at the composite interface to form a strong metallurgical bond.

[0048] The above-described examples are merely for the purpose of illustrating preferred embodiments of the present invention, and are not intended to limit the scope of the present invention. As long as they do not deviate from the design spirit of the present invention, any modifications or improvements made by those skilled in the art to the technical solutions of the present invention should fall within the patent scope of the present invention. [Explanation of symbols]

[0049] 1 workbench 2. Additive Manufacturing System 201 Daiichi Sangyo Robot 202 Heat source 203 Multiple Filament Feed Module 204 Temperature Control Module 205 Adjustment device 3 Casting and rolling systems 301 Casting and rolling mill roller parts 3011 Inlet pipe fitting 3012 Entrance sleeve 3013 Bearings 3014 Casting and rolling roller shaft 30141 Entrance 301411 Entrance hole 30142 Circulation section 301421 Input through hole 301422 Reflux through hole 30143 Exit section 301431 Outlet annular groove 3015 Bearing seat 3016 Casting and rolling roller sleeves 30161 First side shape review section 30162 Central form installation part 30163 Second side shape review section 3017 Outlet sleeve 3018 Outlet pipe fitting 302 Secondary Industry Robots 303 Connection Adjustment Device 4 solid metal 5 Liquid Coated Metal 6 Solid Coated Metal 100 freezing point

Claims

1. A step S1 of preheating the solid metal, in which a temperature control module is turned on to preheat the solid metal, and a temperature measurement sensor is used to detect the preheating temperature of the solid metal in real time, so that the preheating temperature of the solid metal becomes a temperature T1; a step S2 of performing additive manufacturing with the molten heterogeneous filament, in which when the preheating temperature of the solid metal reaches a temperature T1, the first industrial robot coordinates with a plurality of filament feeding modules to transport the solid coated metal filament, and the solid coated metal filament is melted into droplets of liquid coated metal by the action of a heat source, thereby melting and coating the solid metal surface to form a melting pond area, and adjusting and controlling the temperature of the solid metal during melting and coating so that the real-time temperature of the solid metal reaches the temperature T1; Step S3 of combining casting and rolling in situ, in which a coolant is supplied to the inside of the casting and rolling roller, and when the liquid metal and the solid metal form a solid-liquid interface in the melt pool area, the casting and rolling roller parts combine casting and rolling in situ with the solid-liquid, and form a molten and coated metal layer with micro-structures on the surface above the solid metal, in cooperation with the second industrial robot; a step of repeating steps S2 and S3 along a predetermined path to continuously build a form layer by layer above the molten / coated metal layer, forming a three-dimensional object by depositing each layer multiple times, and obtaining a final heterogeneous metal composite material formed by combining additive manufacturing and casting / rolling; a step S4 of measuring a real-time temperature T2 of the molten / coated metal layer with a temperature measurement sensor before and during each layer deposition, and adjusting and controlling the real-time temperature T2 of the molten / coated metal layer so that the real-time temperature T2 is equal to the temperature T1.

2. 2. The method for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ according to claim 1, wherein in step S4, if T2<T1, the temperature control module increases the temperature of the molten / coated metal layer until T2 becomes equal to T1, and then steps S2 and S3 are repeated to perform additive manufacturing and the combination of casting and rolling; whereas if T2>T1, the temperature control module cools the molten / coated metal layer until T2 becomes equal to T1, and then steps S2 and S3 are repeated to perform additive manufacturing and the combination of casting and rolling.

3. The method for additive manufacturing using heterogeneous metals and combining in situ casting and rolling, as described in claim 1, characterized in that in step S2, the first industrial robot links multiple filament feeding modules to transport homogeneous or heterogeneous solid-coated metal filaments according to the performance of the target single element in the molten and coated metal layer, and adjusts the transport speed of multiple types of solid-coated metal filaments to achieve mixing and melting of the solid-coated metal filaments according to the target proportion.

4. 2. The method for combining casting and rolling in situ by additive manufacturing using dissimilar metals, as described in claim 1, wherein in step S3, the outer diameters of the first side shape revision portion and the second side shape revision portion of the casting and rolling roller sleeve in the casting and rolling roller part are larger than the outer diameter of the central shape setting portion, the first side shape revision portion and the second side shape revision portion are pressed inward while contacting both sides of the melt pool region, and the central shape setting portion of the casting and rolling roller sleeve combines casting and rolling in situ while contacting the liquid metal and solidifying the liquid metal into a solid metal after cooling and deformation by rolling.

5. The method for in situ combined casting and rolling by additive manufacturing using dissimilar metals, as described in claim 3, characterized in that in step S2, when the solid coated metal filaments are melted into liquid coated metal droplets by a heat source, the liquid coated metal droplets move downward due to gravity, and when the liquid coated metal droplets move downward in a magnetic field generated by a magnetic field generating device, they are subjected to a Lorentz force, which causes their movement trajectory to be deflected.By changing the magnitude or direction of the current or changing the position of the coil, the direction and strength of the magnetic field can be changed so that the liquid coated metal droplets move toward the casting / rolling roller part and enter the melting pool area.

6. The method for combining in situ casting and rolling by additive manufacturing using dissimilar metals according to claim 2, wherein in step S3, the vibration field means interlocks the casting / rolling roller components to vibrate at high frequency, and when combining in situ casting and rolling of the solid-liquid, the vibration field energy is conducted to near the solidification point within the area where in situ casting and rolling of the solid-liquid is carried out, or the casting / rolling roller components and the solid metal are respectively connected to the positive and negative poles of a pulsed power source to form a closed circuit, and when a pulsed electric field is applied, a pulsed current is applied to near the solidification point within the area where in situ casting and rolling of the solid-liquid is carried out.

7. The system includes a workbench, an additive manufacturing system, and a casting and rolling system installed on both sides of the workbench. The additive manufacturing system includes a first industrial robot, a heat source, a plurality of filament feeding modules, a temperature control module, and an adjustment device, the adjustment device being installed at an end of the first industrial robot, the heat source being installed at a first end of the adjustment device, the plurality of filament feeding modules being connected to a second end of the adjustment device, and the temperature control module being attached to one side of the plurality of filament feeding modules; The casting and rolling system includes a casting and rolling roller component, a second industrial robot, and a connecting and adjusting device, the connecting and adjusting device is installed at the end of the second industrial robot, and the casting and rolling roller component is installed at the front end of the connecting and adjusting device; The casting / rolling roller component includes an entrance sleeve, a casting / rolling roller shaft, a casting / rolling roller sleeve, and an exit sleeve, the entrance sleeve being connected to a first end of the casting / rolling roller shaft, the casting / rolling roller sleeve being disposed at a central position of the casting / rolling roller shaft, and the exit sleeve being connected to a second end of the casting / rolling roller shaft; A device for performing additive manufacturing using dissimilar metals and combining casting and rolling in situ, characterized in that the casting / rolling roller sleeve includes a first side portion shape review portion, a central form setting portion, and a second side portion shape review portion, which are arranged sequentially along the axial direction of the casting / rolling roller sleeve, and the central form setting portion has a spatial form setting on its outer surface.

8. further comprising an energy field system; the energy field system includes one or more of an electromagnetic field means, an oscillating field means, and a pulsed electric field means, the electromagnetic field means being installed near the heat source and the plurality of filament feeding modules, and the liquid coating metal is subjected to a Lorentz force when moving in the electromagnetic field, and is thereby capable of changing its moving trajectory; The vibration field means is installed between the second industrial robot and the connection adjustment device in the casting and rolling system, and is coupled to make the casting and rolling roller parts vibrate at high frequency; 8. The device for performing additive manufacturing using dissimilar metals and combining in situ casting and rolling, as set forth in claim 7, characterized in that the pulsed electric field means is conducted to the casting / rolling roller component and the solid metal via the positive electrode of the pulsed power supply and the negative electrode of the pulsed power supply, respectively, to form a closed circuit, and the pulsed electric field acts on the solidification point in the region where casting and rolling are performed on the solid-liquid in situ.

9. the plurality of filament feed modules are provided with a plurality of filament inlets thereon for transporting the solid coated metal filaments, which may be homogeneous or heterogeneous; The device for additive manufacturing using dissimilar metals and combining in-situ casting and rolling as claimed in claim 8, characterized in that the temperature control module has a temperature measurement sensor attached thereto.

10. The casting / rolling roller shaft includes an inlet portion, a circulation portion, and an outlet portion; 9. The device for additive manufacturing using dissimilar metals and combining in situ casting and rolling as claimed in claim 8, wherein the inlet section has an inlet hole at the center, the outlet section has an outlet annular groove, the circulation section has a plurality of input through holes and return through holes, the input through holes and the inlet hole are connected to each other, the return through holes are connected to the outlet annular groove, and the input through holes and the return through holes are arranged alternately in a sequential and uniform manner along the circumferential direction of the circulation section.

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