Research on Wire Arc Additive Manufacturing in Repairing Irregular Defect based on Reverse Reconstruction

GAO Zhanqi; YANG Yanli; DUAN Jiaxu; WEI Wei; HUANG Zhiquan; XU Liujie

doi:10.7512/j.issn.1001-2303.2024.11.15

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Research on Wire Arc Additive Manufacturing in Repairing Irregular Defect based on Reverse Reconstruction
Vol. 54, Issue 11, Pages: 113-119(2024)
Received：29 September 2024，

Published：25 November 2024
DOI： 10.7512/j.issn.1001-2303.2024.11.15
稿件说明：

移动端阅览

高站起，杨延丽，段嘉旭，等.基于逆向重构的不规则缺陷电弧增材修复研究［J］.电焊机，2024，54（11）：113-119. DOI： 10.7512/j.issn.1001-2303.2024.11.15.

GAO Zhanqi, YANG Yanli, DUAN Jiaxu, et al.Research on Wire Arc Additive Manufacturing in Repairing Irregular Defect based on Reverse Reconstruction[J].Electric Welding Machine, 2024, 54(11): 113-119. DOI： 10.7512/j.issn.1001-2303.2024.11.15.

摘要

采用自制焊接材料，配合主要由Tardis激光视觉相机构成的智能视觉逆向重构系统和由ABB工业机器人、Fronius焊机等构成的电弧丝材增材系统进行人工制造不规则缺陷丝材增材制造修复试验，利用超声探伤、光学显微镜、扫描电子显微镜、能谱分析、性能测试等手段进行不规则缺陷电弧增材成形尺寸偏差、缺陷、组织及性能分析，对丝材电弧增材制造在大型部件不规则缺陷修复的产业化应用进行阐述。结果表明：缺陷深度在30 mm时，采用先边缘再内部填充的路径进行丝材电弧增材制造形成的熔覆金属在成形厚度上尺寸偏差为2 mm；在自动化修复过程中，针对该材料需要每层进行清渣以保证增材熔敷金属质量，避免夹渣缺陷出现；丝材电弧增材制造熔覆金属由铁素体和渗碳体组成，连续作业下不同层数熔覆金属因冷却速度其组织粗化程度差异较为明显，所修复的缺陷区域熔覆金属强度提高4%~5%，延伸率及冲击功下降4%~10%，整体上仍然较为接近焊接材料检验中纯熔覆金属性能。通过逆向重构和丝材电弧增材制造相结合，可以实现大型部件的大尺寸不规则缺修复应用。

Abstract

Research on application of wire arc additive manufacture (WAAM) in repairing irregular defects of large parts was carried out with the intelligent visual reverse reconstruction system mainly composed of Tardis laser vision camera and the WAAM system mainly composed of ABB industrial robots

Fronius welder using welding materials made by ZRIME. Dimensional deviations

defects

microstructure and properties of the multi-layer deposited metal in the irregular area were investigated by UT

SEM

EDS

and the practical application of wire arc additive manufacturing in repairing irregular defects of large parts was described.The results show that when the defect depth was 30 mm

there would be a 2 mm deviation in thickness of the deposited metal using edge to edge then internal filling path by WAAM

the deslagging was necessary for each layer in order to ensure the quality of deposited metal to avoid the slag

the difference of microstructural coarsening degree of deposited metal was obvious due to the cooling rate under almost continuous welding

the strength of cladding metal in the repaired defect area were increased by 4%~5%

and the elongation rate and impact absorbed energy were decreased by 4%~10%

and overall performance was still relatively close to the cladding metal performance in the inspection of welding materials.Through the reverse reconstruction system and WAAM system

large-scale irregular defects of large components could be repaired in industrial applications.

关键词

Keywords

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