Research on arc additive manufacturing and repair of thin-wall aluminum alloy based on reverse modeling

基于逆向建模的铝合金薄壁件电弧增材再修复成形研究 Research on arc additive manufacturing and repair of thin-wall aluminum alloy based on reverse modeling 焦坤 JIAO Kun 1 first-author 赵磊 ZHAO Lei 1 杜行 DU Hang 1 董小媛 DONG Xiaoyuan 1 赵文忠 ZHAO Wenzhong 1 中国电子科技集团公司第二十研究所 中国电子科技集团公司第二十研究所 The 20th Research Institute of CETC The 20th Research Institute of CETC 基于结构光三维扫描尺寸采集技术、Geomagic软件数据处理与逆向重构技术、AMSlicerPro软件模型剖分切片与路径规划技术等,对铝合金ZL114A薄壁件的待修复区域进行逆向建模,通过焊丝ER4043电弧增材再修复试验完成薄壁样件的修复,利用无损探伤、显微硬度计、电子万能试验机及扫描电子显微镜等分析测试手段,对电弧增材再修复样件熔敷区域的性能与组织进行表征。结果表明:成形样件表面无开口缺陷,内部组织致密、无肉眼可见缺陷;修复区域顶部的显微硬度略高于底部,中间区域显微硬度稳定;平行于熔敷方向的试样力学性能均优于垂直于熔敷方向的试样,成形样件力学性能呈现一定的各向异性;修复区域组织Al-Si共晶呈细小条状分布于α固溶体中,并从底部指向顶部延伸,顶部Al-Si共晶分布更加弥散,对α基体的切割效应小,使得其性能比底部更优。 Based on dimension acquisition of structured light 3 D-Scanning technology, data processing and reverse reconstruction of Geomagic, and slicing and path planning of AMSlicer Pro, the lacking part of thin-wall aluminum alloy ZL114 A was modeled in reverse. Through arc additive manufacturing and repair with welding wire ER4043, the lacking part was repaired perfectly. The means of nondestructive testing, microhardness tester, electronic universal testing machine and scanning electron microscopy were used to study and analyze the microstructure and performance of the repaired part in arc additive manufacturing and repair. The results show that the surface of repaired sample has no surface-breaking defect, and the internal microstructure is dense without visible defects. The microhardness at the top of repaired sample is a bit higher than that at the bottom, and the microhardness in the middle part is stable. The mechanical properties of the sample parallel to the direction of arc cladding are superior to those perpendicular to the direction of arc cladding. Therefore, the mechanical properties of repaired sample are anisotropy. The Al-Si eutectic structure of repaired sample showing fine strips distributes in α solid solution, and extends from bottom to top. The Al-Si eutectic structure at the top of repaired sample disperses and has small cutting effect onα matrix, which makes the properties of Al-Si eutectic at the top better than those at the bottom. 铝合金 电弧增材 修复 逆向建模 aluminum alloy arc additive manufacturing repair reverse modeling TG457.14 陕西省重点研发计划项目（2018ZDXM-GY-073） 2022-03-08 10 51