Method for preparing thin-walled preforms by laser metal deposition and follow-up rolling

Abstract

Laser additive manufacturing and a method for preparing thin-walled preforms by laser metal deposition and follow-up rolling. This can solve the problems that when the existing laser metal deposition technology prepares the thin-walled preforms, the limit width size of a molten pool at high power affects the forming wall thickness of the preforms so that it is difficult to prepare preforms with wall thickness less than 2 mm, and the problems of poor surface quality and low accuracy of preforms due to convex and concave peaks caused by the interlayer overlapping, but also can solve the problems that a laser beam with a preset trajectory cannot act on the end surfaces of the preforms due to preform deformation caused by residual stress in a printing process so that the preforms cannot be continuously formed.

Claims

1. A method for preparing thin-walled preforms by laser metal deposition and follow-up rolling, comprising the following steps: step 1. designing thin-walled preforms: analyzing the characteristics of complex thin-walled components, and determining the material and outline sizes of the thin-wall preforms required for hot gas bulging forming of the complex thin-walled components by theoretical calculation or FEM reverse simulation method; the thin-walled preforms comprising thin-walled slabs and thin-walled billets which can be divided into equal wall thickness thin-walled slabs/billets and variable wall thickness thin-walled slabs/billets according to thickness uniformity; step 2. determining process parameters of laser metal deposition: selecting layer thickness according to the structures and shapes of the thin-walled preforms determined in step 1; selecting the layer thickness of the preforms as 0.4-0.6 mm for the equal wall thickness thin-walled slabs/billets; selecting the layer thickness of the preforms as 0.2-0.4 mm for the variable wall thickness thin-walled slabs/billets; a single layer lift of a laser head being equal to the layer thickness of the preforms; determining a laser scanning path according to a layering result obtained after an STL model of the thin-walled preforms is processed by layering slice software; and determining other process parameters of laser metal deposition, comprising laser power, spot diameter, scanning speed, powder feeding rate, gas composition, pressure and flow rate, according to the forming wall thickness and forming requirements of the thin-walled preforms; step 3. determining roller follow-up rolling solutions and process parameters: selecting different follow-up rolling solutions according to the outline sizes of the thin-walled preforms determined in step 1; for preparation of the thin-walled slabs, adopting a solution that a roller conducts integral follow-up rolling on a layer after the layer is printed by laser, or adopting a solution that the roller conducts local follow-up rolling while laser printing; for preparation of the thin-walled billets: adopting the solution that the roller conducts local follow-up rolling while laser printing because the billets have closed sections; for integral follow-up rolling: a roller spacing is equal to the forming wall thickness of the preforms, a roller length is equal to the total length of a single-track single deposition layer, and a roller diameter is equal to the layer thickness of the preforms, wherein a specific calculation process of roller speed is:
h=n.Math.t.sub.1.Math.π.Math.d  (1) where h represents the layer thickness of the preforms, n represents the roller speed, t.sub.1 represents the scanning time of a single-track single layer of the laser head, and d represents the roller diameter;
t.sub.1=L/V  (2) where L represents the total length of the single-track single deposition layer, and V represents laser scanning speed; an expression of the roller speed in the integral follow-up rolling solution is: $\begin{array}{cc}n=\frac{h.Math.V}{\pi .Math.d.Math.L}& \left(3\right)\end{array}$ for local follow-up rolling: a roller spacing is equal to the forming wall thickness of the preforms, an axial roller length is greater than or equal to 3 times the layer thickness of the preforms, and a roller diameter is equal to the layer thickness of the preforms, wherein a specific calculation process of roller speed is:
n.Math.t.sub.2.Math.π.Math.d=V.Math.t.sub.2  (4) where n represents the roller speed, t.sub.2 represents the movement time of the laser head, d represents the roller diameter and V represents laser scanning speed; an expression of the roller speed in the local follow-up rolling solution is: $\begin{array}{cc}n=\frac{V}{\pi .Math.d}& \left(5\right)\end{array}$ step 4. conducting laser printing on an n.sup.th layer and completing follow-up rolling: printing an n.sup.th deposition layer according to the laser metal deposition process parameters determined in step 2 and the roller follow-up rolling solution and process parameters determined in step 3; making the roller and the laser head move synchronously in a printing process; and conducting follow-up rolling on a deposited area after the laser printing; step 5. repeating step 2 to step 4: calculating the total number of laser printing layers according to the total forming height of the thin-walled preforms and the layer thickness determined in step 2; wherein the total number of printing layers is equal to the total forming height of the thin-walled preforms divided by the layer thickness; repeating step 2 to step 4, predicting the deposition of a next layer after printing one layer, and then conducting deposition forming layer by layer, until the thin-walled preforms are printed; step 6. post-processing the thin-walled preforms: after completing the preparation of the thin-walled preforms by laser metal deposition, conducting hot isostatic pressing on the formed thin-walled preforms under high temperature and high pressure conditions to eliminate micro-cracks, gas holes and unfused defects in the thin-walled preforms after laser metal deposition manufacture; and necessarily polishing and cleaning the ends and surfaces of the preforms to obtain the thin-walled preforms which are finally used for forming the complex thin-wall components by hot gas bulging.

2. The method for preparing thin-walled preforms by laser metal deposition and follow-up rolling according to claim 1, wherein in step 2, the preparation of the thin-walled preforms with active properties and easy oxidation reaction is conducted in an argon atmosphere with oxygen content lower than 0.05%; an atmosphere required for the preparation of the thin-walled preforms with good oxidation resistance is adjusted according to the used material.

3. The method for preparing thin-walled preforms by laser metal deposition and follow-up rolling according to claim 1, wherein in step 3, in the local follow-up rolling process solution, the roller conducts follow-up rolling again on a previous deposition layer while conducting follow-up rolling on the deposited area of a current layer.

Description

DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic diagram of a method for preparing thin-walled preforms by laser metal deposition and follow-up rolling in the present invention.

(2) FIGS. 2(a)-2(d) show schematic diagrams of thin-walled preforms to be prepared by the present invention; FIG. 2(a) is an equal wall thickness thin-walled slab; FIG. 2(b) is a variable wall thickness thin-walled slab; FIG. 2(c) is an equal wall thickness thin-walled billet; FIG. 2(d) is a variable wall thickness thin-walled billet.

(3) FIG. 3 is a schematic diagram of an equal wall thickness thin-walled slab prepared by laser metal deposition and integral follow-up rolling in the present invention.

(4) FIG. 4 is a schematic diagram of an equal wall thickness thin-walled slab prepared by laser metal deposition and local follow-up rolling in the present invention.

(5) FIG. 5 is a schematic diagram of a variable wall thickness thin-walled slab prepared by laser metal deposition and local follow-up rolling in the present invention.

(6) FIG. 6 is a schematic diagram of an equal wall thickness thin-walled billet prepared by laser metal deposition and local follow-up rolling in the present invention.

(7) FIG. 7 is a schematic diagram of a variable wall thickness thin-walled billet prepared by laser metal deposition and local follow-up rolling in the present invention.

(8) In the drawings: 1 equal wall thickness thin-walled slab; 2 variable wall thickness thin-walled slab; 3 equal wall thickness thin-walled billet; 4 variable wall thickness thin-walled billet; 5 laser head; 6 powder feeder; 7 powder nozzle; 8 substrate; 9 rotating spindle; 10 workbench; 11 slide rail; 12 roller steering; 13 roller.

DETAILED DESCRIPTION

(9) Specific embodiments of the present invention are further described below in combination with the drawings and the technical solutions.

(10) Embodiment 1: in combination with the illustration of FIG. 1, FIGS. 2(a)-2(d), FIG. 3, FIG. 4, FIG. 5, FIG. 6 and FIG. 7, the present invention proposes a method for preparing thin-walled preforms by laser metal deposition and follow-up rolling. The method is conducted according to the following steps:

(11) Step 1. designing thin-walled preforms: analyzing the characteristics of complex thin-walled components, and determining the material and outline sizes of the thin-wall preforms required for hot gas bulging forming of the complex thin-walled components by theoretical calculation or FEM reverse simulation method.

(12) Step 2. determining process parameters of laser metal deposition: selecting layer thickness according to the structures and shapes of the thin-walled preforms determined in step 1; selecting the layer thickness of the preforms as 0.4-0.6 mm for the equal wall thickness thin-walled slabs/billets; selecting the layer thickness of the preforms as 0.2-0.4 mm for the variable wall thickness thin-walled slabs/billets; a single layer lift of a laser head being equal to the layer thickness of the preforms; determining a laser scanning path according to a layering result obtained after an STL model of the thin-walled preforms is processed by layering slice software; and determining other process parameters of laser metal deposition, comprising laser power, spot diameter, scanning speed, powder feeding rate, gas composition, pressure and flow rate, according to the forming wall thickness and forming requirements of the thin-walled preforms; and conducting the preparation of the thin-walled preforms in an argon atmosphere with oxygen content lower than 0.05%.

(13) Step 3. determining roller follow-up rolling solutions and process parameters: selecting different follow-up rolling solutions according to the outline sizes of the thin-walled preforms determined in step 1; for preparation of the thin-walled slabs, adopting a solution that a roller conducts integral follow-up rolling on a layer after the layer is printed by laser, or adopting a solution that the roller conducts local follow-up rolling while laser printing; for preparation of the thin-walled billets, adopting the solution that the roller conducts local follow-up rolling while laser printing because the billets have closed sections;

(14) for integral follow-up rolling: a roller spacing is equal to the forming wall thickness of the preforms, a roller length is equal to the total length of a single-track single deposition layer, and a roller diameter is equal to the layer thickness of the preforms, wherein a specific calculation process of roller speed is:
h=n.Math.t.sub.1.Math.π.Math.d  (1)

(15) where h represents the layer thickness of the preforms, n represents the roller speed, t.sub.1 represents the scanning time of a single-track single layer of the laser head, and d represents the roller diameter;
t.sub.1=L/V  (2)

(16) where L represents the total length of the single-track single deposition layer, and V represents laser scanning speed;

(17) an expression of the roller speed in the integral follow-up rolling solution is:

(18) $\begin{array}{cc}n=\frac{h.Math.V}{\pi .Math.d.Math.L}& \left(3\right)\end{array}$

(19) for local follow-up rolling: a roller spacing is equal to the forming wall thickness of the preforms, an axial roller length is greater than or equal to 3 times the layer thickness of the preforms, and a roller diameter is equal to the layer thickness of the preforms, wherein a specific calculation process of roller speed is:
n.Math.t.sub.2.Math.π.Math.d=V.Math.t.sub.2  (4)

(20) where n represents the roller speed, t.sub.2 represents the movement time of the laser head, d represents the roller diameter and V represents laser scanning speed;

(21) an expression of the roller speed in the local follow-up rolling solution is:

(22) $\begin{array}{cc}n=\frac{V}{\pi .Math.d}& \left(5\right)\end{array}$

(23) in the local follow-up rolling solution, the roller conducts follow-up rolling again on a previous deposition layer while conducting follow-up rolling on the deposited area of a current layer.

(24) Step 4. conducting laser printing on an n.sup.th layer and completing follow-up rolling: printing an n.sup.th deposition layer according to the laser metal deposition process parameters determined in step 2 and the roller follow-up rolling solution and process parameters determined in step 3 (n is 1, 2, 3, etc.); making the roller and the laser head move synchronously in a printing process; and conducting follow-up rolling on a deposited area after the laser printing.

(25) Step 5. repeating step 2 to step 4: calculating the total number of laser printing layers according to the total forming height of the thin-walled preforms and the layer thickness determined in step 2; wherein the total number of printing layers is equal to the total forming height of the thin-walled preforms divided by the layer thickness; repeating step 2 to step 4, predicting the deposition of a next layer after printing one layer, and conducting deposition forming layer by layer, until the thin-walled preforms are printed.

(26) Step 6. post-processing the thin-walled preforms: after completing the preparation of the preforms by laser metal deposition, conducting hot isostatic pressing on the formed thin-walled preforms at 910° C. and 120 MPa under thermal insulation to eliminate micro-cracks, gas holes and unfused defects in the thin-walled preforms after laser metal deposition manufacture; and necessarily polishing and cleaning the ends and surfaces of the preforms to obtain the thin-walled preforms which can be finally used for forming the complex thin-wall components by hot gas bulging.

(27) The present embodiment has the following beneficial effects: the method for preparing thin-walled preforms by laser metal deposition and follow-up rolling uses the roller to conduct follow-up rolling on the deposited area completed by laser metal deposition, which can solve the problems that when the existing laser metal deposition prepares thin-walled preforms, the limit width size of a molten pool at high power affects the forming wall thickness of the preforms and thus it is difficult to prepare thin-walled preforms with wall thickness less than 2 mm, and the convex and concave peaks caused by the interlayer overlapping lead to poor surface quality and low accuracy of the preforms. Moreover, the method can achieve the effect of rectification on the deposited area, to avoid the problem that a laser beam with a preset trajectory cannot act on the end surfaces of the preforms due to deformation caused by residual stress in the printing process so that the preforms cannot be continuously formed. In addition, the method can also adjust the spacing of the rolls according to the forming wall thickness requirements of different characteristic areas of the thin-walled preforms to prepare equal wall thickness and variable wall thickness thin-walled preforms and simultaneously improve the density and microstructure performance uniformity of the thin-walled preforms.

(28) Embodiment 2: in combination with the illustration of FIG. 3, in step 2 to step 5, when the equal wall thickness thin-walled slabs are prepared, a technical solution of integral follow-up rolling is adopted. Within the time of printing a next layer by the laser head, the roller completes the integral follow-up rolling on a previous layer, and two motion states are independent of each other. The roller spacing can be adjusted through a slide rail. Other steps are the same as those of embodiment 1.

(29) The present embodiment has the following beneficial effects: the roller spacing can be adjusted through the slide rail; the roller spacing is adjusted according to the forming wall thickness of the preforms; and the equal wall thickness and variable wall thickness thin-walled preforms can be prepared. The roller conducts integral follow-up rolling on the deposition layer after printing to achieve an effect of rectification on the deposition layer, to avoid the problem that a laser beam with a preset trajectory cannot act on the end surfaces of the preforms due to deformation caused by residual stress so that the preforms cannot be continuously formed.

(30) Embodiment 3: in combination with the illustration of FIG. 4 and FIG. 5, in step 2 to step 5, when the equal wall thickness thin-walled slabs or variable wall thickness thin-walled slabs are prepared by laser metal deposition, a solution that the laser head and the roller move back and forth synchronously is adopted. In the process of moving back and forth, a deflection angle of the roller needs to be adjusted so that the roller keeps a line contact state with the deposited area. Other steps are the same as those of embodiment 1.

(31) The present embodiment has the following beneficial effects: by adopting the solution that the laser head and the roller move back and forth synchronously, the roller can conduct real-time local follow-up rolling on the deposited area after printing, which can solve the problems of poor surface quality and low accuracy of preforms due to convex and concave peaks caused by the interlayer overlapping. Only the rotation speed and angle of the roller need to be controlled in the printing process. In addition, the material density and microstructure performance uniformity of the deposited area can also be improved.

(32) Embodiment 4: in combination with the illustration of FIG. 6 and FIG. 7, in step 2 to step 5, when the equal wall thickness thin-walled billets or variable wall thickness thin-walled billets are prepared by laser metal deposition, a solution that the laser head and the roller move back and forth synchronously in the same direction is adopted. In the process of moving in the same direction with the laser head, a rotation angle of the roller needs to be adjusted through a guideway rotating shaft so that the roller always keeps a line contact state with the deposited area. Other steps are the same as those of embodiment 1.

(33) The present embodiment has the following beneficial effects: some billets with smaller diameters, especially variable wall thickness thin-walled billets can be realized by adjusting the roller spacing, which can not only improve the forming quality of the inner walls and the outer walls of the billets, but also can solve the problem of outward flow of liquid metal in the molten pool during laser metal deposition. The present embodiment has the advantages of saving expensive powder material and shortening the manufacturing cycle of the thin-walled preforms.