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CN-121976262-A - Magnetically assisted electrochemical additive manufacturing micro-component system and precision regulation and control method

CN121976262ACN 121976262 ACN121976262 ACN 121976262ACN-121976262-A

Abstract

A micro-component system for magnetically assisted electrochemical additive manufacturing and an accuracy regulation method comprise a peristaltic pump, a magnetic field device, an electrolytic tank, a power supply, a current detection device and a control device, wherein the air floatation table is arranged on a workbench, the air floatation table is used for keeping the surface of a cathode in a horizontal state in a printing process, a printing head precise triaxial moving table is connected with an anode, a high-speed optical microscope triaxial moving table is connected with a high-speed optical microscope and is arranged on the electrolytic tank and is opposite to the cathode, a scanning electrochemical cell microscope is arranged on the printing head precise triaxial moving table, electrolyte is contained in the electrolytic tank, the peristaltic pump is connected with the electrolytic tank and circularly flows the electrolyte in the electrolytic tank, the magnetic field device is arranged on the air floatation table and is positioned on two sides of the electrolytic tank and is used for providing magnetic field environments with different intensities in a deposition process. The invention solves the problems of low consistency of deposition thickness, frequent occurrence of deposition defects and unstable crystal grain crystallization in the current electrochemical additive manufacturing.

Inventors

  • LI LIANGLIANG
  • YUE LINGFENG
  • CHEN JIE
  • LV JIAYAN
  • Bian Jianxiao
  • AN YIFEI
  • ZHANG LINSHENG

Assignees

  • 陇东学院

Dates

Publication Date
20260505
Application Date
20260305

Claims (7)

  1. 1. The magnetically assisted electrochemical additive manufacturing micro-component system is characterized by comprising a peristaltic pump (1), a magnetic field device (2), an electrolytic tank (3), a scanning electrochemical cell microscope (4), a high-speed optical microscope (5), an anode (6), a printing head precision triaxial moving table (7), a high-speed optical microscope triaxial moving table (8), a power supply and current detection device (9), a control device (10), an air floatation table (11), a cathode (12), an electrolyte (13) and a workbench (14); The peristaltic pump (1), the magnetic field device (2), the electrolytic tank (3), the power supply and current detection device (9) and the control device (10) are arranged on the air floatation table (11), the air floatation table (11) is arranged on the workbench (14), the air floatation table (11) is used for keeping the cathode surface at the level in the printing process, the printing head precision triaxial moving table (7) is connected with the anode (6), the high-speed optical microscope triaxial moving table (8) is connected with the high-speed optical microscope (5) and is arranged on the electrolytic tank (3) and is opposite to the cathode (12), the scanning electrochemical cell microscope (4) is arranged on the printing head precision triaxial moving table (7), and the electrolyte (13) is contained in the electrolytic tank (3); The peristaltic pump (1) is connected with the electrolytic tank (3) to circularly flow the electrolyte (13) in the electrolytic tank (3), and the magnetic field device (2) is arranged on the air floatation table (11) and positioned at two sides of the electrolytic tank (3) and is used for providing magnetic field environments with different intensities in the deposition process.
  2. 2. The magnetically assisted electrochemical additive manufacturing micro component system according to claim 1, wherein the high-speed optical microscope triaxial moving table (8) is connected with the high-speed optical microscope (5), so that the high-speed optical microscope (5) can move in three directions above the cathode X, Y, Z, and a dynamic deposition morphology of the surface of the cathode (12) is obtained; The printing head precision triaxial moving table (7) is connected with the anode (6), the scanning electrochemical cell microscope (4) is arranged on the printing head precision triaxial moving table (7), the path planning of the control device (10) is executed, the tip of the anode (6) can move in the direction facing to the cathode 12 and above X, Y, Z, and therefore the forming of printing pieces is achieved.
  3. 3. A magnetically assisted electrochemical additive manufacturing micro-component system according to claim 1, characterized in that the power supply and current detection means (9) are connected to the anode (6) and the cathode (12), provide the electric field required for magnetically assisted electrochemical additive manufacturing, and enable testing of the current in the reaction circuit; the control device (10) is respectively connected with the magnetic field device (2), the printing head precise triaxial mobile station (7), the high-speed optical microscope triaxial mobile station (8), the high-speed optical microscope (5), the scanning electrochemical cell microscope (4) and the power supply and current detection device (9) and is used for precisely controlling the dynamic deposition morphology through the connecting devices.
  4. 4. A magnetically assisted electrochemical additive manufacturing micro-component system according to claim 1, characterized in that the control device (10) comprises a path planning module, an image generation module and a print adjustment module; The path planning module is used for planning a printing path for realizing the printing target physics; the image generation module is used for dynamically displaying the appearance of the workpiece by using the high-speed optical microscope (5) in the printing process to generate a printing image; The printing adjustment module is used for dynamically adjusting the X, Y, Z direction of the anode (6) according to the shape of the workpiece and the current detection, and executing the printing path of the path planning module.
  5. 5. The magnetically assisted electrochemical additive manufacturing micro component system of claim 4, wherein the path planning module comprises a three-dimensional modeling module, a hierarchical slicing module, a data processing module, an add support points module, an extract all points module, and a visualization module; the three-dimensional modeling module creates a three-dimensional model of the expected microstructure by using 3D design software and stores the three-dimensional model as a binary STL file; The layering slicing module reads an STL file by using Ultimaker Cura software, cuts a part along the Z direction, identifies the part outline, creates a filling pattern and generates a (Gcode) file, and the whole model is divided into two parts, namely an outer wall outline and an inner filler; The data processing module first calculates the distance "L" between two points according to the actual printing voxel spacing d of the anode, such that n=floor (L/d), for data points in the "fill" field, if n=0, it means that the two points are too close, in which case the midpoint between them is calculated as an additional deposition point, if n >0, it means that the two data points are too far apart, new n deposition points need to be inserted, for wall data, it means that the distance between a and B is smaller than the "spacing" value, in which case point B is discarded, the calculation continues between points a and C, and if n >0, the data processing method follows the same method as when n >0 in the "fill" field; The support point adding module is used for connecting printing paths between two adjacent layers, finding out that two points closest to a deposited voxel plane between the two adjacent layers are an upper layer M and a lower layer N respectively, starting from the lower layer N, calculating a straight line distance L between the points M and N to determine whether additional support points are needed or not, setting n=floor (L/d) as before, if n=0, taking the point N as the support of the point M, not needing interpolation, and reordering a data string from N, and if N >0, taking the data string lack of support points, thus M and N are used as starting points and end points of vectors, and then adding N interpolation points at each interval as the support points; The all-point extraction module is used for extracting data obtained by the data processing module and the supporting point adding module to form a (& CSV) file; The visualization module uses MATLAB to dynamically animate (.csv) files.
  6. 6. The magnetically assisted electrochemical additive manufacturing micro component system of claim 4, wherein the print adjustment module comprises a speed control module, a position control module, and a correction control module; The speed control module is used for judging whether feedback of the printed image meets typical defect initiation critical conditions of occurrence of air holes, inclusions and microcracks on the deposition surface; The specific judgment mode is that the air hole detects the current sharp change degree through a current detection device (9), the current signal fluctuates by more than 30%, which indicates that an electrode gap conductive medium between an anode (6) and a cathode (12) changes, a large amount of hydrogen is generated in the reaction process, so as to change the current value in a circuit, an electrochemical current change generated by the oxidation of micro-area substances is detected through a scanning electrochemical cell microscope (4), when the oxidation current suddenly increases, the generation of oxides in the additive manufacturing process is predicted to cause the generation of impurities, a micro-crack detects the size of the crack through a high-speed optical microscope (5), and when the voxel gap is larger than 1 mu m, the aspect ratio is larger than 10, the generation of the crack is indicated; If not, continuing printing until the printing path is completed. If yes, utilizing a dynamic process condition and instantaneous microstructure evolution relation model to adjust printing parameters, further changing printing speed until a feedback signal does not meet a defect germination critical condition, and controlling an anode (6) to continue printing until the whole printing path is completed based on the processing speed under the process parameter condition; the position control module judges whether the height of a printing voxel point in the printing image is consistent with that of a model setting printing layer by using a scanning electrochemical cell microscope (4), if so, the printing of the current voxel point is continued until the layer height is met, and then the printing of the next voxel point is carried out; In the correction control module, after one layer is printed, the image generation module generates a printed image on the layer, detects whether the whole product layer is a plane, judges whether the basis is a curved surface threshold value, namely that the difference between the lowest point and the highest point on the curved surface is smaller than the layer height, if so, continues to print the next layer, and if not, enters a correction path; the correction path is used for repairing the problem of layer distortion caused by error accumulation and edge effect in the printing process, and performing surface fitting on the printed image, wherein the fitted surface equation is expressed as: The tangential plane equation corresponding to the curved surface, i.e., the layer plane constraint equation, is: wherein x, y and z are coordinate values of points on an actual curved surface fed back by a printed image, A, B, C, R is a preset deposition plane equation coefficient of the model, m is the layer height of the current layer, and a constant. The point i on the curved surface is vertically projected onto the tangent plane along the Z-axis direction to obtain a corresponding plane point, and the coordinate difference of the two points in the Z-axis direction is that The method comprises the steps of determining the distance to be moved to a tangential plane in the repairing process of any point on a curved surface, dispersing the fitting curved surface into M deposition points by taking the diameter D of a printing head as a circle, and starting the repairing, wherein the three-dimensional coordinate of the ith deposition point D i is (x i ,y i ,z i ) and the dwell time is t i = The growth rate of v, v is given by using the Faraday equation after coupling the magnetic field, and when the deposition of the D i point is finished, the print head is located on the tangential plane D i （x i ,y i ,z i + ) It is ensured that the print head is moved to the next deposition point D i+1 （x i+1 ,y i+1 ,z i+1 ) in the anode and cathode connected state, and the above-described operation is repeated until all deposition points on the curved surface are corrected to the tangential plane.
  7. 7. A method for precision control of a magnetically assisted electrochemical additive manufacturing micro-component system according to any of claims 1-6, comprising the steps of: (1) Three-dimensional modeling, namely finishing the three-dimensional structure design of the prefabricated member by using three-dimensional design software, and storing the three-dimensional structure design as a binary STL file; (2) Slicing by layering, namely reading an STL file by using Ultimaker Cura software, cutting a part along the Z direction at a fixed layer height, identifying the part contour, creating a filling pattern and generating a (Gcode) file, wherein the whole model is divided into two parts, namely an outer wall contour and an inner filler; (3) Data processing-for filled data, the distance "L" between two points is first calculated such that n=floor (L/d), for data points in the "filled" field, if n=0, it means that the two points are too close. In this case, the midpoint between them is calculated as the additional deposition point; If n >0, it means that two data points are too far apart, a new n deposition points need to be inserted, data between the two points is calculated for wall data, and if n=0, it means that the distance between a and B is smaller than the "pitch" value. In this case point B is discarded and the calculation continues between points A and C, if n >0, the data processing method follows the same method as when n >0 in the "fill" field; (4) The method comprises the steps of adding supporting points, finding out two points closest to a deposited voxel plane between two adjacent layers, namely an upper layer M and a lower layer N respectively, and calculating a straight line distance L between the points M and N from the lower layer N to determine whether additional supporting points are needed or not, wherein the two points are the upper layer M and the lower layer N respectively; As before, let n=floor (L/d). If n=0, point N is the support for point M, interpolation is not needed, the data string reorders from N, and if N >0, the data string lacks support points, so M and N serve as the start and end points of the vector. Then adding n interpolation points at each interval as supporting points; (5) Extracting all points, and obtaining data by a data processing module and a supporting point adding module to form a (& CSV) file; (6) Visualization, namely performing dynamic animation display on (. CSV) files by using MATLAB, and checking the planned files; (7) Placing CuSO 4 ﹒5H 2 O into a beaker, adding deionized water for dilution, adding sulfuric acid for PH, placing into a constant-temperature water bath, applying magnetic stirring, and adding into an electrolytic tank (3) after stirring uniformly; (8) Mounting an anode (6) and a scanning electrochemical cell microscope (4) on a printing head precision triaxial moving table (7); (9) The high-speed optical microscope (5) is arranged on a three-axis mobile table (8) of the high-speed optical microscope, and the morphology of the surface of the cathode (12) can be clearly displayed through a control device (10); (10) The cathode (12) is arranged in the electrolytic tank (3) and is fixed by a non-conductive polyvinyl acetate screw; (11) Adjusting the magnetic field intensity of the magnetic field module (2), measuring the magnetic induction intensity of the reaction micro-area by using an HT20 digital Gaussian meter, and adjusting the magnetic induction intensity to the required magnetic field intensity; (12) Two ends of a power supply (8) are respectively connected with an anode (6) and a cathode (12), parameters of external voltage, frequency and duty ratio are adjusted, the power supply is turned on to lead current to the anode and the cathode, and the interelectrode voltage of 1-4V, the pulse current duty ratio of 0.5-0.8 and the pulse frequency of 1-2 kHz are adjusted according to printing requirements; (13) The distance between the anode (6) and the cathode (12) is adjusted through a control system on a computer, when the current suddenly increases from 0 to a fixed value along with the approach of the anode (6) to the cathode (12), the cathode and the anode are indicated to be conducted, the anode (6) moves 10 mu m towards the positive direction of the Z axis at the moment, the electrode distance is adjusted to be 10 mu m, a power supply (8) is turned off at the moment, electrolyte (13) is added, and the adjustment principle is that when the anode and the cathode are not connected, the state corresponds to an off state, the current in the current is zero at the moment, and the position of the current in the circuit indicates that the cathode and the anode are in a conducting state; (14) Opening a peristaltic pump, and adjusting the flow to 4-10 ml/min according to printing conditions; (15) A control device (10) controls the movement of the anode (6) in the X, Y, Z direction by a (. CSV) file of the running path planning, so that the model micro-part is formed according to a CAD model; (16) In the printing process, a high-speed optical microscope (5) image generating module generates a deposition printing image, a position control module in a printing adjustment module judges whether the printing voxel point in the printing image is consistent with the height of a printing layer set by a model, if so, printing of the next voxel point is started, a speed control module detects whether typical defect initiation critical conditions such as air holes, inclusions, microscopic cracks and the like on the deposition surface are met, if so, the processing speed under the condition of adjusting process parameters is met, and all path planning is completed under the position control module, a correction control module detects whether the whole part layer meets a curved surface threshold value, if so, the next layer printing is stopped, the correction path is started until all deposition points on the curved surface are corrected to a tangent plane, and the next layer printing is started, so that all layers of printing is completed.

Description

Magnetically assisted electrochemical additive manufacturing micro-component system and precision regulation and control method Technical Field The invention belongs to the technical field of metallogy and metal technology, and particularly relates to a magnetically assisted electrochemical additive manufacturing micro-component system and an accuracy regulation method. Background Electrochemical additive manufacturing (ECAM) utilizes directional reduction and deposition of metal ions under an electric field, and can theoretically realize atomic-scale material accumulation at normal temperature and normal pressure, and is considered as one of ideal ways for realizing high-performance metal micro-nano structure manufacturing. The electrochemical additive manufacturing technology is a non-thermal metal additive manufacturing technology and is widely applied to the field of micro-manufacturing. Electrochemical additive manufacturing techniques combine electrodeposition techniques and additive manufacturing techniques to deposit thin and highly adherent metal layers onto conductive substrate surfaces by reducing metal ions in solution. Additive manufactured molded part quality can be improved by applying a magnetic field. Currently, more than 10 ECAM techniques, represented by jet, partial shielding, meniscus confinement, etc., have made preliminary progress in shaping micron-scale wire/post structures. However, the technology has a fundamental scientific obstacle towards practical application, namely, firstly, the relation between the growth thickness of a microstructure and the current density shows that the uniformity of the current density distribution in a cathode surface has an important influence on the quality of a deposited layer, however, the electric field edge effect is aggravated due to uneven flow field and ion mass transfer limitation in a micron-sized processing gap, and the adsorption and diffusion nonuniformity of the metal ions at the gap are aggravated due to micro-vibration of anode movement, so that the current density distribution on the cathode surface is spontaneously unstable. For example, wu Wenzheng et al discloses a device and a method for manufacturing miniature metal parts by meniscus electrochemical additive on demand, namely a device and a method for manufacturing a micro anode by local electrochemical deposition additive on demand (application number: CN 202310505511.8), wherein the printing mode has non-uniform growth of a deposition layer which is thick in the middle and thin in the edge, and severely restricts high-fidelity shaping of a complex three-dimensional morphology, and secondly, the point-by-point/layer reduction deposition of metal atoms is a dynamic transient process involving electric field, flow field, ion concentration field and electrochemical reaction multi-field intensity coupling. Therefore, xu Jinkai et al, "additive manufacturing apparatus and method based on meniscus confinement electrodeposition," have the advantage that over time, electrochemical deposition rates exhibit significant non-linear characteristics, making it difficult to precisely control the growth characteristics of three-dimensional structures. Wu Wang an equal and artificial improvement of the quality of a workpiece is disclosed as an electrochemical additive manufacturing device and method for improving the quality of the workpiece (application number: CN 202310937434.3), which can prevent the workpiece from being deteriorated due to the short circuit of a cathode and an anode to a certain extent due to the change of the electrode gap, but the prevention of internal defects such as air holes, inclusions and the like and the deposition thickness fluctuation defect caused by uneven flow fields lacks theoretical guidance, so that the mechanical performance and the reliability of a formed workpiece are difficult to ensure. Third, no path planning software is currently available to implement path planning for magnetic field assisted electrochemical additive manufacturing because the data obtained by common fused 3D printing software such as Ultimaker Cura is generated from a print head diameter of 0.4mm, which is 20 times different from the anode diameter of 0.02mm for magnetic field assisted electrochemical additive manufacturing, and further commercial slicing software such as layer count indicators, layer specific identifiers, fan activation control, nozzle acceleration settings and extrusion volume adjustment are an integral part of conventional 3D printing operations, but lack applicability in magnetic field assisted electrochemical additive manufacturing systems because the deposition rate of electrochemical additive manufacturing is directly determined by multiple physical field coupling parameters. This has led to the inability of current commercial software to be directly applied in the field of electrochemical additive manufacturing. Therefore, a set of perfect high-performance me