| ZHANG Bo-yang,LI Xu,ZHANG Yu-jiao,LI Ying-hao,ZONG Ran.Research Status of Arc Additive Manufacturing of Aluminum Alloy[J],52(11):111-127 |
| Research Status of Arc Additive Manufacturing of Aluminum Alloy |
| Received:September 06, 2022 Revised:December 24, 2022 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2023.11.009 |
| KeyWord:aluminum alloy arc additive manufacturing heat input current mode energy field |
| Author | Institution |
| ZHANG Bo-yang |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| LI Xu |
Shandong Yuehao Automation Equipment Company Limited, Shandong Linyi , China |
| ZHANG Yu-jiao |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| LI Ying-hao |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
| ZONG Ran |
School of Mechanical Engineering, Shandong University of Technology, Shandong Zibo , China |
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| Abstract: |
| 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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