Control Strategies for UFP-TIG Wire-Arc Additive Manufacturing Process of Aluminum Alloy Frame Components

SUN Xuejun; YAN Huixing; LI Wenshuo; JIANG Zihao; CONG Baoqiang; JIANG Kun; YANG Kai

doi:10.7512/j.issn.1001-2303.2026.07.01

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Control Strategies for UFP-TIG Wire-Arc Additive Manufacturing Process of Aluminum Alloy Frame Components
Vol. 56, Issue 7, Pages: 1-9(2026)
Received：22 June 2026，

Revised：2026-07-08，

Published：20 July 2026
DOI： 10.7512/j.issn.1001-2303.2026.07.01
稿件说明：

移动端阅览

孙雪君，闫慧星，李文硕，等.铝合金框类构件UFP-TIG电弧熔丝工艺成形控制策略［J］.电焊机，2026，56（7）：1-9. DOI： 10.7512/j.issn.1001-2303.2026.07.01.

SUN Xuejun, YAN Huixing, LI Wenshuo, et al.Control Strategies for UFP-TIG Wire-Arc Additive Manufacturing Process of Aluminum Alloy Frame Components[J].Electric Welding Machine, 2026, 56(7): 1-9. DOI： 10.7512/j.issn.1001-2303.2026.07.01.

摘要

铝合金框类构件在航空航天领域应用广泛，但电弧熔丝增材制造过程中，熄弧、弯折和交叉等位置特征易产生缩颈、堆高、下塌等成形缺陷，严重制约构件的尺寸精度与制造效率。本文基于UFP-TIG电弧熔丝制造系统，分析了框类构件三类典型位置特征缺陷的形成机制，提出了多参数协同成形控制方法。针对熄弧位置，提出电流-送丝-运动协同衰减策略，熄弧位置与中部高度差由20%降至0.54%；针对弯折位置，依据角度特征分别采用圆弧过渡、角点转动和端部搭接方法，150°、90°、30°构件弯折位置高度偏差分别由1.2%、4.7%、18.6%降至0.19%、0.45%、0.9%；针对交叉位置，利用TIG工艺传热与传质过程可独立调控的优势，提出“跨越”控制方法，交叉位置与周围平均高度差由14.96%降至8.56%。在此基础上开展了典型框类构件工艺验证试验，试制构件沉积效率达500 cm

/h以上，不同位置最大相对高度差控制在6%以内。

Abstract

Aluminum alloy frame components are widely used in the aerospace field. However

during wire-arc additive manufacturing

characteristic positions such as arc termination

bending

and crossing are prone to forming defects including necking

local bulging

and collapse

which seriously constrain the dimensional accuracy and manufacturing efficiency. Based on the UFP-TIG wire-arc additive manufacturing system

this study analyzed the formation mechanisms of defects at three typical characteristic positions and proposed a multi-parameter collaborative forming control method. For the arc termination position

a collaborative attenuation strategy of current

wire feeding

and motion was proposed

reducing the height difference between the arc termination and middle sections from 20% to 0.54%. For bending positions

arc transition

corner rotation

and end overlapping methods were adopted according to the angle characteristics

and the height deviations at 150°

90°

and 30° bending positions were reduced from 1.2%

4.7%

and 18.6% to 0.19%

0.45%

and 0.9%

respectively. For crossing positions

a "crossing" control method was proposed based on the independent controllability of heat and mass transfer processes in the TIG process

reducing the height difference between the crossing point and the surrounding average height from 14.96% to 8.56%. Process validation tests on typical frame components were conducted

achieving a deposition efficiency exceeding 500 cm³/h with the maximum relative height difference at different positions controlled within 6%.

关键词

Keywords

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