CN110238395B - Method for additive manufacturing of printed metal parts by means of prefabricated sand moulds - Google Patents
Method for additive manufacturing of printed metal parts by means of prefabricated sand moulds Download PDFInfo
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- CN110238395B CN110238395B CN201910564303.9A CN201910564303A CN110238395B CN 110238395 B CN110238395 B CN 110238395B CN 201910564303 A CN201910564303 A CN 201910564303A CN 110238395 B CN110238395 B CN 110238395B
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/30—Process control
- B22F10/36—Process control of energy beam parameters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/60—Treatment of workpieces or articles after build-up
- B22F10/66—Treatment of workpieces or articles after build-up by mechanical means
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Powder Metallurgy (AREA)
Abstract
The invention belongs to the technical field of additive manufacturing, and provides a method for manufacturing printed metal parts through prefabricated sand mold additive manufacturing. Firstly, preparing a prefabricated sand molding piece by a 3D ink-jet printing technology, then printing a metal part at the printing position of the prefabricated sand molding piece by using metal powder, then printing a metal support, and spraying the metal powder on the surface of the prefabricated sand molding piece before printing each time for surface treatment until the molding of the metal part and the metal support is finished. And dissolving the prefabricated sand mold by using a dissolving agent, and finally removing the metal support and the substrate by using machining to obtain the metal part. The invention prevents the defect of printing failure caused by the collapse of a molten pool due to no structural support in the powder feeding/wire feeding printing stage, avoids redundant mechanical processing, reduces the molding cost of metal parts with complex structures, and meets the market demand.
Description
Technical Field
The invention relates to the field of additive manufacturing, and particularly provides a method for printing a complex metal part based on prefabricated sand mold powder feeding/wire feeding in additive manufacturing.
Background
3D printing is now used in the casting field more often, and the common techniques are: fused deposition rapid prototyping (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS), mold-less casting (PCM), 3D inkjet printing (3 DP). 3DP is an ideal forming mode for replacing the traditional casting mold and casting core, the operations of casting mold, sand mixing and the like are not needed in the forming process, and the traditional industry and the additive manufacturing technology are perfectly fused. The 3DP is utilized to produce the casting mold and the casting core, so that the development of 3D printing is promoted, and the technical innovation of the casting industry is promoted.
The sand mould printing sand mould raw and other materials are special, raise dust does not appear in the printing process, and the effect between the sand mould and the adhesive is carried out in a relatively closed box body, so that the pollution to the environment is reduced, and the harm to a human body is reduced. Secondly, 3D prints the manufacturing mould and has saved the process of preparation mould, when practicing thrift the cost, has improved the flexibility of product production. And thirdly, the 3D printing improves the precision and the quality of the product, and the capability of forming complex parts is greatly enhanced. A series of researches on the combination of additive manufacturing and sand mold printing are carried out by relevant experts and scholars at home and abroad:
the university of Qinghua's national forever group (Lu Q, Du Z, YanY, et al, study on multifunctionality Manufacturing system [ J ]. Integrated Manufacturing Systems,1998,9(4):236 and 241.) conducted intensive research at 3DP, which consisted of laying a layer of powder, spraying an adhesive onto the part to be formed with a nozzle, then adhering the powder to the part surface, then continuously laying powder, spraying, adhering, and laminating layer by layer to form the final part.
Duyanqiang (Duyanqiang. 3D printing difficulty of large casting sand core shallow analysis [ J ]. metalworking (hot working), 2016(15):17-19.) researches show that 3D printed sand core is easy to exhaust, poor in deformability and fixity, and difficult to put in a core frame and a core exhaust pipe. Therefore, the sand core is printed to form a structure with an external cooling iron slot, but experiments show that the workload of sand supplementing and gap filling is still needed due to the size problem.
The optimization design method of the sand mold structure for the 3D printing is researched by the Yangtai-Guo-Tech (Yangtai-Guo, Yokou, etc. [ J ]. mechanical engineering, 2017(21):169-177.) to carry out optimization design aiming at the relationship between the sand mold structure and the load distribution in the pouring process, and deduces the mathematical formula of the sand mold thickness design in three directions. As shown in formulas (1) to (3). Through the simulation design and the calculation optimization of the structure, the sand mold structure optimization design is proved to be capable of effectively controlling the load distribution of the pouring gate, and the economic benefit and the scientificity of the 3D printing sand mold are improved.
Wherein T is the optimized thickness, σ b is the tensile strength, k is the allowable coefficient of mechanical deformation, n is the allowable coefficient of bending stress, and m is the allowable coefficient of shearing stress.
However, in the laser melting deposition technology (powder feeding printing), due to the fact that the diameter of a laser spot is large, the printing precision is not enough, the part is deformed due to large thermal stress in the forming process, and the forming complex part is poor in capability due to the fact that a molten pool does not have a supporting function in the printing process. And the arc additive manufacturing technology (wire feeding printing) also collapses the molten pool due to the non-support effect under the action of the large heat of the arc.
The researches only aim at the aspects of firstly 3D printing of sand moulds, sand cores and then sand mould casting, and the like, and are finally applied to casting. There is no improvement in the ability to shape complex parts for laser fused deposition (powder fed printing) and arc additive manufacturing techniques (wire fed printing) in additive manufacturing, and thus this problem is in great demand.
Disclosure of Invention
The invention aims to provide a method for manufacturing printed metal parts through prefabricated sand mould additive manufacturing.
The above object of the invention is achieved by the features of the independent claims, the dependent claims developing the features of the independent claims in alternative or advantageous ways.
In order to achieve the purpose, the invention provides a method for printing metal parts through prefabricated sand mold additive manufacturing, which takes a prefabricated sand mold part as a first support, takes metal support parts arranged between the prefabricated sand mold parts at intervals along the horizontal direction of a substrate as a second support, and prints the metal parts on the surface of a support structure formed by the prefabricated sand mold part and the metal support parts by adopting an additive manufacturing technology, wherein the specific printing steps are as follows: firstly, placing a prefabricated sand mold on a substrate, before printing a metal part, spraying metal powder on a printing position on the prefabricated sand mold for surface treatment, then printing the metal part by adopting an additive manufacturing technology, then printing a metal support piece attached to the prefabricated sand mold on the substrate, after printing is finished, placing a corresponding prefabricated sand mold on the substrate, and repeating the printing process until a complete metal part is printed.
Further, the prefabricated sand mold is printed by a 3D ink jet printing technology (3 DP).
Further, the pre-made sand is printed with molding sand and binder using 3D inkjet printing technology (3 DP).
Further, the metal part or/and the metal support is subjected to powder feeding printing by adopting a laser additive manufacturing technology.
Further, the metal part or/and the metal support is wire-fed printed by adopting an electric arc additive manufacturing technology.
Further, when the metal parts and the metal supports are printed by powder feeding, the printing height is 0.6-0.8 mm, the laser power is 900-1500 w, the scanning speed is 480-720 mm/min, and the scanning distance is 1.7 mm.
Further, when the metal part and the metal support are printed by wire feeding, the printing height is 1-1.5 mm, the wire feeding printing adopts a CMT welding technology, and the wire feeding speed is 7.5-8.5 m/min; the welding speed is 0.006-0.01 m/s; dry extension 8 mm; the air flow rate is 25L/min.
Furthermore, in the supporting structure formed by the prefabricated sand part and the metal supporting piece, the prefabricated sand part is made of any one of the following materials: silicon dioxide, aluminum oxide, silicon nitride, graphite and the like, and the metal support comprises any one of the following materials: stainless steel, titanium alloy, copper alloy, aluminum alloy, and the like.
Furthermore, the material of the metal powder is consistent with that of the metal part.
Furthermore, in the supporting structure formed by the prefabricated sand-shaped parts and the metal supporting parts, the number of the prefabricated sand-shaped parts is not less than 1, one metal supporting part is arranged at intervals of 2-10 mm, and preferably one metal supporting part is arranged at intervals of 4-6 mm.
Further, after printing is finished, the metal support is removed by machining.
Further, after printing is finished, the prefabricated sand mold piece is removed in a dissolving mode through a dissolving agent.
Further, when the metal part is of an axisymmetric structure, the printing sequence is sequentially and symmetrically printed from two ends to the middle of the metal part, and the method comprises the following specific steps: placing a prefabricated sand mold part corresponding to the first end or the second end of the metal part on a substrate, before printing the metal part, spraying metal powder on the printing position of the prefabricated sand mold part for surface treatment, printing the first end or the second end of the metal part by adopting an additive manufacturing technology, then printing a metal support part attached to the prefabricated sand mold part on the substrate, after printing of the two ends of the metal part is finished, correspondingly placing the next prefabricated sand mold part on the substrate according to the printing sequence, repeating the printing process until the complete metal part is printed, and after the whole printing is finished, sequentially removing the prefabricated sand mold part, the metal support part and the substrate to obtain the metal part.
Further, when the metal part is in a non-axisymmetric structure, the printing sequence is that the metal part is sequentially printed from the first end to the second end, and the specific steps are as follows: placing a prefabricated sand mold corresponding to the first end of the metal part on a substrate, before printing the metal part, spraying metal powder to perform surface treatment on the printing position of the prefabricated sand mold, printing the first end of the metal part by adopting an additive manufacturing technology, then printing a metal support part attached to the prefabricated sand mold on the substrate, after printing of the first end is finished, correspondingly placing the next prefabricated sand mold on the substrate according to the printing sequence, repeating the printing process until the complete metal part is printed, and after printing is finished, sequentially removing the prefabricated sand mold, the metal support part and the substrate to obtain the metal part.
The method for manufacturing the printed metal part through the prefabricated sand mold additive has the remarkable advantages that: the metal parts and the metal supporting structures with complex structures are printed by using the prefabricated sand mold powder feeding/wire feeding, and the defect of printing failure caused by collapse of a molten pool due to no structural support in the powder feeding/wire feeding printing stage is avoided in the printing process. But through the prefabricated sand mould and the metal support piece, the function of supporting the molten pool is played. After the metal parts are molded, the prefabricated sand-type part is dissolved by using a dissolving agent, and then only a few supports need to be removed, so that redundant machining is avoided, the molding cost of the metal parts with complex structures is reduced, and the market demand is met.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent. In addition, all combinations of claimed subject matter are considered a part of the presently disclosed subject matter.
The foregoing and other aspects, embodiments and features of the present teachings can be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of specific embodiments in accordance with the teachings of the present invention.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, corresponding operational steps in the various figures are labeled with words. For purposes of clarity, not every step may be described in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
fig. 1 is a flow chart of the present invention for additive manufacturing powder feed/wire feed printed metal parts by pre-sand molding.
Fig. 2 is a schematic cross-sectional view of a powder fed printed metal part made by additive manufacturing of pre-sand molds according to the present invention.
Fig. 3 is a schematic cross-sectional view of a powder fed printed metal part made by additive manufacturing of pre-sand molds according to the present invention.
Fig. 4 is a schematic cross-sectional view of a powder fed printed metal part made by additive manufacturing of pre-sand molds according to the present invention.
Fig. 5 is a schematic cross-sectional view of a wire-fed printed metal part made by additive manufacturing of a pre-manufactured sand mold according to the present invention.
Fig. 6 is a schematic cross-sectional view of a powder fed printed metal part made by additive manufacturing of pre-sand molds according to the present invention.
Detailed Description
In order to better understand the technical content of the present invention, specific embodiments are described below with reference to the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be appreciated that the various concepts and embodiments described above, as well as those described in greater detail below, may be implemented in any of numerous ways, as the disclosed concepts and embodiments are not limited to any one implementation. In addition, some aspects of the present disclosure may be used alone, or in any suitable combination with other aspects of the present disclosure.
The disclosure according to the present invention is directed to a method for additive manufacturing of printed metal parts by prefabricated sand mould additive manufacturing. Firstly, preparing a prefabricated sand molding piece by a 3D ink-jet printing technology (3DP), then carrying out powder feeding/wire feeding printing on a printing position of the prefabricated sand molding piece to print a metal part, then printing a metal support, and spraying metal powder on the surface of the prefabricated sand molding piece before each printing to carry out surface treatment until the molding of the metal part and the metal support is finished. And dissolving the prefabricated sand mold by using a dissolving agent, and finally removing the metal support and the substrate by using machining to obtain the metal part.
As an exemplary implementation of the present invention, as shown in fig. 1, the foregoing specific implementation process includes:
step 1, firstly, designing the shape and the number of prefabricated sand parts according to the shape of a metal part to be printed, reserving the positions and the number of metal supporting pieces arranged among the prefabricated sand parts at intervals along the horizontal direction of a base plate, arranging one metal supporting piece on the base plate at intervals of 2-10 mm, and attaching a supporting structure formed by all the prefabricated sand parts and the metal supporting pieces to the inner wall of the metal part to be printed.
And 2, printing the designed prefabricated sand-type part by using a 3D ink-jet printing technology (3DP), wherein the printing material is molding sand and a resin binder (the addition amount of the binder is 1.8-2%).
And 3, firstly placing a prefabricated sand mold part on the substrate, spraying metal powder on a corresponding position (printing position) on the prefabricated sand mold part for surface treatment before printing the metal part, and then printing the metal part by adopting an additive manufacturing technology.
And 4, after the first part of the metal part is printed, printing the metal supporting piece attached to the prefabricated sand mold piece on the substrate, then placing the next part of the prefabricated sand mold piece, and repeating the step 2 until the complete metal part is printed.
And 5, dissolving the resin binder in the prefabricated sand-shaped part by using a dissolving agent so as to disperse the bonded molding sand, thereby achieving the purpose of removing the prefabricated sand-shaped part.
And 6, removing the metal support by using machining to obtain the required metal part.
Therefore, the metal part is printed through the prefabricated sand mold in the process, the prefabricated sand mold is dissolved by the dissolving agent, the metal supporting structure is removed through machining, and the possibility of printing the part with the complex structure through additive manufacturing powder feeding is realized.
It should be clear that, when printing the metal parts, the printing sequence is not fixed, and the metal parts may be sequentially printed from left to right (or from right to left), may be symmetrically printed from two ends to the middle, and may be randomly unordered. When the metal part is in an axisymmetric structure, the printing sequence is preferably symmetrical from two ends of the metal part to the middle of the metal part; and when the metal part is in a non-axisymmetric structure, the printing sequence is preferably sequentially printed from the first end to the second end of the metal part.
To facilitate a better understanding, the invention is further described below with specific reference to the following 6 additive examples, in which the metal support and the pre-sand mold may be selected from the group consisting of alloy powder/wire and sand materials in pairs, including, for example, a combination of steel and silica, a combination of titanium alloy and alumina, a combination of copper alloy and silicon nitride, and a combination of aluminum alloy and graphite. However, the types of the alloy powder/wire material and the molding sand material are not limited to the various powder/wire material and molding sand material compositions listed in the examples, and the present disclosure includes, but is not limited to, the combination of the materials in the examples.
[ MEANS FOR IMPLEMENTING I ]
(1) And designing the shape of the prefabricated sand type pieces (namely prefabricated sand type parts) by combining the structure of the metal part shown in the figure 2, determining the number of the prefabricated sand type pieces to be 4, reserving the positions and the number of the metal supporting pieces (namely metal supports) longitudinally arranged among the prefabricated sand type pieces at intervals, and meeting the requirement that a supporting structure formed by 4 prefabricated sand type pieces and 3 metal supporting pieces is attached to the inner wall of the metal part to be printed.
(2) And printing the prefabricated sand mold of the silicon dioxide by using a 3D ink-jet printing technology (3DP) for later use, wherein the binder is 1.8-2 wt% of clay.
(3) With reference to fig. 2(a) to 2(i), the sand pre-cast component corresponding to the first end of the metal part is first placed on a substrate (i.e., a metal substrate), and before each part is printed, 301 stainless steel metal powder is first sprayed onto the printing position of the sand pre-cast component by using a spray head to perform surface treatment. After the surface treatment is finished, powder feeding printing 301 of the stainless steel metal part is carried out on the printing position of the prefabricated sand mould part by adopting an additive manufacturing technology (laser melting deposition). The printing parameters were as follows: the single-layer printing height is 0.6mm, the laser power is 900W, the scanning speed is 500mm/min, and the scanning interval is 1.7 mm.
(4) And after the printing of the first part 301 stainless steel metal part is finished, printing a metal support part attached to the prefabricated sand mould part on the substrate, then putting the prefabricated sand mould part corresponding to the second end of the metal part, and repeating the step 2 until the complete 301 stainless steel metal part is printed according to the printing sequence from the two ends to the middle of the metal part.
(5) And soaking the printed and molded metal part, the metal support and the prefabricated sand mold part in an alcohol dissolving agent, and removing the prefabricated sand mold part after dissolving off the adhesive clay.
(6) And removing the metal support and the substrate by using machining to obtain the required 301 stainless steel metal part.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different sand mold materials and metal types.
[ PREPARATION II ]
(1) And designing the shape of the prefabricated sand type pieces (namely prefabricated sand type parts) by combining the structure of the metal part shown in the figure 2, determining the number of the prefabricated sand type pieces to be 4, reserving the positions and the number of the metal supporting pieces (namely metal supports) longitudinally arranged among the prefabricated sand type pieces at intervals, and meeting the requirement that a supporting structure formed by 4 prefabricated sand type pieces and 3 metal supporting pieces is attached to the inner wall of the metal part to be printed.
(2) And printing the prefabricated sand mold of the alumina by using a 3D ink-jet printing technology (3DP) for later use, wherein the binder is 1.8-2 wt% of clay.
(3) With reference to fig. 2(a) to 2(i), the sand preform corresponding to the first end of the metal part is first placed on a substrate (i.e., a metal substrate), and then, before each part is printed, a TC4 titanium alloy metal powder is first sprayed onto the printing position of the sand preform for surface treatment. After the surface treatment is finished, adopting an additive manufacturing technology (laser melting deposition), and feeding powder to print TC4 titanium alloy metal parts on the printing position of the prefabricated sand mold part. The printing parameters were as follows: the single-layer printing height is 0.7mm, the laser power is 1000W, the scanning speed is 560mm/min, and the scanning interval is 1.7 mm.
(4) And after the printing of the first part of TC4 titanium alloy metal parts is finished, printing a metal support attached to the prefabricated sand mold on the substrate, then putting the prefabricated sand mold corresponding to the second end of the metal part, repeating the step 2, and printing from two ends to the middle of the metal part until a complete TC4 titanium alloy part is printed.
(5) And soaking the printed and molded metal part, the metal support and the prefabricated sand mold part in an alcohol dissolving agent, and removing the prefabricated sand mold part after dissolving off the adhesive clay.
(6) And removing the metal support and the substrate by using mechanical processing to obtain the required TC4 titanium alloy metal part.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different types of molding sand materials and metals.
[ MEANS FOR CARRYING OUT III ]
(1) And designing the shape of the prefabricated sand type pieces (namely prefabricated sand type parts) by combining the structure of the metal part shown in the figure 3, determining the number of the prefabricated sand type pieces to be 4, reserving the positions and the number of the metal supporting pieces (namely metal supports) longitudinally arranged among the prefabricated sand type pieces at intervals, and meeting the requirement that a supporting structure formed by the 4 prefabricated sand type pieces and the 3 metal supporting pieces is attached to the inner wall of the metal part to be printed.
(2) And printing the silicon nitride prefabricated sand mold by using a 3D ink-jet printing technology (3DP) for later use, wherein the binder is 1.8-2 wt% of sodium silicate.
(3) With reference to fig. 3(a) to 3(e), the sand preform corresponding to the first end of the metal part is first placed on a substrate (i.e., a metal substrate), and before each part is printed, a cu alloy powder of CuSn10 is first sprayed onto the printing position of the sand preform to perform a surface treatment. After the surface treatment is finished, adopting an additive manufacturing technology (laser melting deposition) to perform powder feeding printing on the CuSn10 copper alloy metal part at the printing position of the prefabricated sand mold part. The printing parameters were as follows: the single-layer printing height is 0.8mm, the laser power is 1100W, the scanning speed is 600mm/min, and the scanning interval is 1.7 mm.
(4) And after the printing of the first part of CuSn10 copper alloy metal parts is finished, printing metal supporting pieces attached to the prefabricated sand mold pieces on the substrate, sequentially putting the prefabricated sand mold pieces corresponding to the metal parts, repeating the step 2, and sequentially printing complete CuSn10 copper alloy metal parts according to the printing sequence from the first end to the second end of the metal parts.
(5) And soaking the printed metal part, the metal support and the prefabricated sand mold part in an alcohol dissolving agent, and removing the prefabricated sand mold part after dissolving off the sodium silicate serving as a binder.
(6) And removing the metal support and the substrate by using mechanical processing to obtain the required CuSn10 copper alloy metal part.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different types of molding sand materials and metals.
[ PREPARATION IV ] A
(1) And designing the shape of the prefabricated sand type pieces (namely prefabricated sand type parts) by combining the structure of the metal part shown in fig. 4, determining the number of the prefabricated sand type pieces to be 4, reserving the positions and the number of the metal supporting pieces (namely metal supports) longitudinally arranged among the prefabricated sand type pieces at intervals, and meeting the requirement that a supporting structure formed by the 4 prefabricated sand type pieces and the 3 metal supporting pieces is attached to the inner wall of the metal part to be printed.
(2) And printing the graphite prefabricated sand mold by using a 3D ink-jet printing technology (3DP) for later use, wherein the binder is 1.8-2 wt% of phenolic resin.
(3) With reference to fig. 4(a) to 4(i), the sand preform corresponding to the first end of the metal part is first placed on a substrate (i.e., a metal substrate), and then, before each part is printed, a surface treatment is performed by spraying metal powder of AlSi10Mg aluminum alloy onto the printing position of the sand preform. After the surface treatment is finished, the AlSi10Mg aluminum alloy metal part is subjected to powder feeding printing on the printing position of the prefabricated sand mold part by adopting an additive manufacturing technology (laser melting deposition). The printing parameters were as follows: the single-layer printing height is 0.8mm, the laser power is 1500W, the scanning speed is 720mm/min, and the scanning interval is 1.7 mm.
(4) And after the first part of the AlSi10Mg aluminum alloy metal parts are printed, printing a metal support piece attached to the prefabricated sand mold piece on the substrate, then putting the prefabricated sand mold piece corresponding to the second end of the metal part, repeating the step 2, and printing from two ends to the middle of the metal part until the complete AlSi10Mg aluminum alloy metal parts are printed.
(5) And soaking the printed metal part, the metal support and the prefabricated sand mold part in an alcohol dissolving agent, and removing the prefabricated sand mold part after dissolving the phenolic resin of the binder.
(6) And removing the metal support and the substrate by using mechanical processing to obtain the required AlSi10Mg aluminum alloy metal part.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different sand mold materials and metal types.
[ PREPARATION III ] A
(1) And designing the shape of the prefabricated sand type pieces (namely prefabricated sand type parts) by combining the structure of the metal part shown in the figure 5, determining the number of the prefabricated sand type pieces to be 5, reserving the positions and the number of the metal supporting pieces (namely metal supports) longitudinally arranged among the prefabricated sand type pieces at intervals, and meeting the requirement that a supporting structure formed by the 5 prefabricated sand type pieces and the 4 metal supporting pieces is attached to the inner wall of the metal part to be printed.
(2) And printing the silica prefabricated sand mold by using a 3D ink-jet printing technology (3DP) for later use, wherein the binder is 1.8-2 wt% of furan resin.
(3) With reference to fig. 5(a) to 5(e), the sand preform corresponding to the first end of the metal part is first placed on a substrate (i.e., a metal substrate), and TC4 titanium alloy metal powder is first sprayed onto the printing position of the sand preform by a nozzle for surface treatment before each part is printed. After the surface treatment is finished, the TC4 titanium alloy metal part is subjected to wire-feeding printing at the printing position of the prefabricated sand mold part by adopting an additive manufacturing technology (an arc additive manufacturing technology). The CMT printing parameters are as follows: the wire feeding speed is 7.5 m/min; the welding speed is 0.006 m/s; dry extension 8 mm; the air flow is 25L/min;
(4) and after the printing of the first part of TC4 titanium alloy metal parts is finished, printing a metal support piece attached to the prefabricated sand mold piece on the substrate, then putting the prefabricated sand mold piece corresponding to the second end of the metal part, repeating the step 2, and printing from two ends to the middle of the metal part until a complete TC4 titanium alloy metal part is printed.
(5) And soaking the printed metal part, the metal support and the prefabricated sand mold part in an alcohol dissolving agent, and removing the prefabricated sand mold part after dissolving off the furan resin as a binder.
(6) And removing the metal support and the substrate by using mechanical processing to obtain the required TC4 titanium alloy metal part.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different sand mold materials and metal types.
[ PREPARATION IV ] A
(1) And designing the shape of the prefabricated sand type pieces (namely prefabricated sand type parts) by combining the structure of the metal part shown in fig. 6, determining the number of the prefabricated sand type pieces to be 6, reserving the positions and the number of the metal supporting pieces (namely metal supports) longitudinally arranged among the prefabricated sand type pieces at intervals, and meeting the requirement that a supporting structure formed by the 6 prefabricated sand type pieces and the 2k metal supporting pieces is attached to the inner wall of the metal part to be printed.
(2) And printing the prefabricated sand mold of the alumina by using a 3D ink-jet printing technology (3DP) for later use, wherein the binder is 1.8-2 wt% of clay.
(3) With reference to fig. 6(a) to 6(i), the sand preform corresponding to the first end of the metal part is first placed on a substrate (i.e., a metal substrate), and then, before each part is printed, the metal powder of the TC4 titanium alloy is first sprayed onto the printing position of the sand preform for surface treatment. After the surface treatment is finished, adopting an additive manufacturing technology (laser melting deposition), and feeding powder to print TC4 titanium alloy metal parts on the printing position of the prefabricated sand mold part. The printing parameters were as follows: the single-layer printing height is 0.6mm, the laser power is 900W, the scanning speed is 420mm/min, and the scanning interval is 1.7 mm.
(4) And after the printing of the first part of TC4 titanium alloy metal parts is finished, printing a metal support attached to the prefabricated sand mold on the substrate, then putting the prefabricated sand mold corresponding to the second end of the metal part, repeating the step 2, and printing from two ends to the middle of the metal part until a complete TC4 titanium alloy part is printed.
(5) And soaking the printed and molded metal part, the metal support and the prefabricated sand mold part in an alcohol dissolving agent, and removing the prefabricated sand mold part after dissolving off the adhesive clay.
(6) And removing the metal support and the substrate by using mechanical processing to obtain the required TC4 titanium alloy metal part.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different types of molding sand materials and metals.
The specific technological parameters of the implementation can adopt corresponding technological parameters according to different types of molding sand materials and metals. In the field of additive manufacturing, laser melting deposition (powder feeding printing) and electric arc additive manufacturing technology (powder feeding printing) have the effect of supporting a molten pool by powder because of not melting in a laser selective area (powder spreading printing), and the molten pool is easy to collapse when complex parts are molded, so that the molding of the complex parts fails. In the embodiment of the invention, the prefabricated sand mold is introduced in the printing process to play a role of setoff the powder feeding/wire feeding printing molten pool, so that printing failure caused by collapse of the molten pool in the printing process is avoided, meanwhile, the influence of thermal stress on molding in the powder feeding/wire feeding printing process is reduced through the printing metal support, and the capability of powder feeding/wire feeding printing of parts with complex structures is improved.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.
Claims (10)
1. A method for manufacturing printed metal parts through prefabricated sand molds in an additive mode is characterized in that the prefabricated sand molds are used as first supports, metal supports arranged between the prefabricated sand molds at intervals along the horizontal direction of a base plate are used as second supports, the metal parts are printed on the surface of a supporting structure formed by the prefabricated sand molds and the metal supports through the additive manufacturing technology, and the specific printing steps are as follows:
firstly, placing a prefabricated sand mold on a substrate, before printing a metal part, spraying metal powder on the printing position of the prefabricated sand mold for surface treatment, then printing the metal part by adopting an additive manufacturing technology, then feeding the material on the substrate to print a metal support piece attached to the prefabricated sand mold, after printing is finished, placing the next prefabricated sand mold on the substrate, and repeating the printing process until the complete metal part is printed;
wherein, the supporting structure formed by all the prefabricated sand parts and the metal supporting pieces is attached to the inner wall of the metal part to be printed.
2. The method of claim 1, wherein the metal powder is formed of a material consistent with a material of the metal part.
3. The method of claim 1, wherein the pre-sand molded part is printed using 3D inkjet printing techniques.
4. The method of claim 1, wherein the metal part or/and the metal support is powder fed printed using additive manufacturing techniques.
5. The method of claim 1, wherein the metal part or/and the metal support is wire-fed printed using additive manufacturing techniques.
6. The method according to claim 1, wherein the prefabricated sand parts and the metal supporting parts form a supporting structure, the number of the prefabricated sand parts is not less than 1, and one metal supporting part is arranged at intervals of 2-10 mm.
7. The method of claim 1, wherein the material of the pre-sand mold comprises any one of: silicon dioxide, alumina, silicon nitride, graphite, the metal part is the same with metal support's material, includes any one of following: stainless steel, titanium alloy, copper alloy, aluminum alloy.
8. The method of claim 1, further comprising the step of sequentially removing the pre-made sand element, the metal support and the substrate after printing is completed.
9. The method as claimed in claim 1, wherein when the metal part has an axisymmetric structure, the printing sequence is symmetrically printed from two ends to the middle of the metal part in sequence, and the specific steps are as follows: placing a prefabricated sand mold part corresponding to the first end or the second end of the metal part on a substrate, spraying metal powder on the printing position of the prefabricated sand mold part for surface treatment before printing the metal part, printing the first end or the second end of the metal part by adopting an additive manufacturing technology, printing a metal support part attached to the prefabricated sand mold part on the substrate, correspondingly placing the next prefabricated sand mold part on the substrate according to the printing sequence after printing of the two ends of the metal part is finished, and repeating the printing process until the complete metal part is printed.
10. The method of claim 1, wherein when the metal part is non-axisymmetric, the printing sequence is sequential from the first end to the second end of the metal part by the steps of: placing a prefabricated sand mold corresponding to the first end of the metal part on a substrate, before printing the metal part, spraying metal powder to perform surface treatment on the printing position of the prefabricated sand mold, printing the first end of the metal part by adopting an additive manufacturing technology, then printing a metal support part attached to the prefabricated sand mold on the substrate, after printing of the first end is finished, correspondingly placing the next prefabricated sand mold on the substrate according to the printing sequence, and repeating the printing process until the complete metal part is printed.
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