张铂洋,李旭,张玉娇,李英豪,宗然.铝合金电弧增材制造研究现状[J].表面技术,2023,52(11):111-127.
ZHANG Bo-yang,LI Xu,ZHANG Yu-jiao,LI Ying-hao,ZONG Ran.Research Status of Arc Additive Manufacturing of Aluminum Alloy[J].Surface Technology,2023,52(11):111-127 |
| 铝合金电弧增材制造研究现状 |
| Research Status of Arc Additive Manufacturing of Aluminum Alloy |
| 投稿时间：2022-09-06 修订日期：2022-12-24 |
| DOI：10.16490/j.cnki.issn.1001-3660.2023.11.009 |
| 中文关键词: 铝合金 电弧增材 热输入 电流方式 外加能场 |
| 英文关键词:aluminum alloy arc additive manufacturing heat input current mode energy field |
| 基金项目:国家自然科学基金(51905321);山东省精密制造与特种加工重点实验室 |
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| Author | Institution |
| ZHANG Bo-yang | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| LI Xu | Shandong Yuehao Automation Equipment Company Limited, Shandong Linyi 276000, China |
| ZHANG Yu-jiao | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| LI Ying-hao | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
| ZONG Ran | School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo 255000, China |
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| 中文摘要: |
| 电弧增材制造技术(Wire Arc Additive Manufacturing，WAAM)具有沉积速率高，成形速度快以及适合各种成形环境的优点，吸引了越来越多的高校及科研机构投入其中，如何进一步发挥电弧增材制造的优势是当下的研究热点。阐述了铝合金电弧增材过程中热输入、电流方式和外加能场对成形件表面形貌、微观组织以及力学性能的影响。当焊接电流较小或焊接速度较快时，热输入较低，熔融金属冷却速度快，形核率高，成形件为晶粒细小的等轴晶粒，提供给气孔的形成、聚集和长大的时间短，即热输入越低，成形件等轴晶区越宽，晶粒越细小，气孔缺陷越少，成形件机械性能越优异。对比分析了不同电流方式的电弧增材制造成形件性能差异，发现脉冲和变极性电流方式的热输入比无脉冲电流方式低，成形件晶粒更精细、缺陷更少、机械性能更优异;脉冲和变极性电流方式都可以清理成形件表面氧化膜，获得平整的表面。分析了电弧增材制造系统的优化方案，发现施加磁场、激光可以使得电弧更加集中，调控熔池流动，避免熔敷金属铺展不均匀;施加原位轧制、层间锤击以及超声喷丸可使得沉积层发生变形，在晶粒内产生大量位错;利用水箱或者添加保护气喷嘴可以降低电弧增材过程的热输入，获得晶粒细小、气孔缺陷少的成形件。最后提出了电弧增材铝合金现阶段存在的问题以及解决方法。 |
| 英文摘要: |
| Aluminum alloys have advantages of low density and high specific strength, so they are widely used in lightweight design fields such as aerospace and automobiles. With the development of the aerospace and automotive industries, aluminum alloy structural parts have developed towards high precision, large size and complex shapes, which puts forward higher requirements for the manufacturing technology of aluminum alloy parts. Wire Arc Additive Manufacturing (WAAM) has the advantages of high deposition rate, fast forming speed and is suitable for various forming environments, attracting more and more universities and scientific research institutions for investigation. How to make full use of the advantages of WAAM to reduce or avoid defects in WAAM is a research hotpot. The effect of heat input, current waveform and external energy field on the surface morphology, microstructure, and mechanical properties of the WAAM parts is expounded. It is found that when the welding current is small or the welding speed is fast, the heat input of the WAAM is small. Therefore, the melting metal cooling speed is fast, the nucleation rate is high, the grain does not have enough time to grow up, so the forming part has fine equiaxed grains. When the heat input is low, the time for the formation, aggregation and growth of pores is shorter. In other words, the lower heat input, the wider equiaxed crystal zone, the smaller grains, the less pore defects, and the better mechanical properties of the forming parts. The reasons for the different properties of WAAM with different current modes were analyzed. It was found that the heat input of pulse current and variable polarity current mode was lower than that of no pulse current mode, and the oxide film on the surface of the forming part could be cleaned, so that the forming part with flat surface could be obtained. The optimization scheme of arc additive manufacturing system was analyzed. It was found that applying magnetic field and laser could make the arc more concentrated, control the molten pool flow, and avoid the uneven spread of molten metal. In situ rolling, interlayer hammering and ultrasonic shot peening could deform the sedimentary layer and produce a large number of dislocations in the grain. The heat input of arc additive could be reduced by using water tank or adding protective gas nozzles, and the formed parts with small grains and fewer porosity defects could be obtained. At present, the research of arc additive manufacturing of aluminum alloy mainly focuses on:reducing heat input by changing wire feeding speed, traveling speed and current mode and combining molding with other equipment to reduce the air hole defect of arc additive molding parts. However, the process parameters require a lot of experiments, which requires a lot of material cost and time cost. In the future, in order to make arc additive manufacturing technology be better applied to aluminum alloy manufacturing, it is necessary to develop a composite arc additive system with multi-energy field co-convergence, and adjust process parameters associated; establish the process parameters database and realize the sharing of manufacturing data; combine the numerical simulation with the experiment, verify the rationality of the simulation through the experiment, and explain the defects in the forming process and the mechanism of microstructure evolution from the perspectives of temperature field, flow field and stress field in the arc additive process, so as to guide the experiment. |
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