最新刊期
期 2 ， 2023
西南交通大学 熊俊教授
- 摘要：As an essential branch of metal additive manufacturing, wire and arc additive manufacturing (WAAM), using an arc as the energy beam to melt metal wire layer by layer, has shown broad application prospects in aerospace and defense fields due to its advantages of low manufacturing cost, high forming efficiency, and high material utilization. The decoupling control of heat input of deposited layers and wire melting efficiency is a key scientific and technical problem that must be solved to promote the efficient and high-quality development and application of WAAM. The main reasons for the strong coupling of forming heat input and forming efficiency are analyzed. Research progress and shortcomings of existing efficient forming methods, heat accumulation control measures, and low heat input heat sources are highlighted. The main development direction of low heat input and efficient forming for wire and arc additive manufacturing in the future is pointed out.关键词：wire and arc additive manufacturing;heat input;deposition rate;heat accumulation
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发布时间：2023-03-02 - 摘要：Wire arc additive manufacturing is a highly efficient and rapid near-net forming technology. Due to its significant advantages of low cost and high flexibility, it has become a hot research topic and the preferred choice for the manufacturing of medium/large parts. It is widely used in core equipment manufacturing fields such as aerospace, weapons and so on. In this paper, the recent research of wire arc additive manufacturing in forming trajectory and process planning is reviewed. The three-dimensional model slicing method, the two-dimensional contour path planning method with different geometric characteristics, the special path planning strategy of typical structure and the optimization and control strategy of forming process parameters are summarized. The technological methods to improve the surface quality and forming accuracy in various aspects, the non-support printing strategy of overhang and inclined structure are introduced. Finally, the current research progress of wire arc additive manufacturing is summarized, and the resreach direction of improving the intelligent of arc welding additive manufactuing equipment and process control in the future is pointed out.关键词：wire arc additive manufacturing;process planning;slicing method;path planning
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发布时间：2023-03-02 - 摘要：Digital twin technology is a simulation process integrated by multi-discipline, multi-physical quantity, multi-scale and multi-probability through comprehensively using of physical model, sensor information and operation history data. Combined with additive manufacturing to realize the intelligent interconnection of the physical world and the information world, it becomes a potential approach to reduce trial-and-error experiments of process parameters, control the mechanical performance of additively manufactured components, and save the costs of the process. The background and significance of digital twin driving additive manufacturing is discussed, the key elements of building a digital twin system for additive manufacturing is introduced, and the developments and challenges of 3D model design, slicing and path planning, mechanism model, sensing and control, statistical model, big data and machine learning of additive manufacturing are clarified. Finally, the future research trends and focus of digital twin driven additive manufacturing is revealed.关键词：additive manufacturing;digital twins;intelligent manufacturing;digital model;real-time sensing;data analysis;forecast and control
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发布时间：2023-03-02 - 摘要：As one of the important structural materials, magnesium alloys are important for lightweight manufacturing of aerospace equipment components. Wire-arc additive manufacturing technology provides a new technical route for the manufacturing of large, monolithic, high-performance metal components which are difficult to fabricate through conventional methods. By the means of wire-arc additive manufactured magnesium alloys, it can effectively meet the urgent needs for lightweight, low energy consumption, high quality and high efficiency in aerospace equipment manufacturing. This paper summarizes the research results and progress at home and abroad in the field of wire-arc additive manufactured magnesium alloys and the influence of different wire-arc additive manufacturing processes on forming control and performance improvement of magnesium alloy components systematically. The forming characteristics, microstructure evolution, metallurgical defects and mechanical properties of wire-arc additive manufactured magnesium alloys are discussed from three aspects of forming quality, structural properties and internal defects control. Furthermore, the existing problems and future research directions of wire-arc additive manufactured magnesium alloys are pointed out.关键词：magnesium alloys;wire-arc additive manufacturing;forming quality;solidification defects;microstructure and properties
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发布时间：2023-03-02 - 摘要：Additive manufacturing technology is an important component of manufacturing information, digitalization and intelligence, and arc additive technology has better application advantages in aluminum alloy forming. The advantages and limitations of different additive manufacturing technologies are compared and analyzed from the aspects of metal additive manufacturing technology classification, development history, standard specification and technology principle. In particular, the arc additive technology, represented by cold metal transition technology, is introduced, and the advantages and limitations of the arc additive technology itself and its advantages of application to the integrated manufacturing of aluminum alloy structural parts are discussed. The research and development of domestic and international arc additive technology for aluminum alloys are reviewed in terms of forming process, porosity defects, toughening technology, etc. The current research work and main problems encountered in the direction of arc additive manufacturing for aluminum alloys are introduced, the toughening methods and effects of arc additive manufacturing samples for aluminum alloys are analyzed, and relevant excellent cases at home and abroad are introduced. Finally, we summarize the problems and possible directions that need to be addressed in the future arc additive manufacturing technology for aluminum alloys, including:raw material quality, geometric accuracy, porosity, thermal cracking and residual stress, and organization and mechanical properties.关键词：wire arc additive manufacturing;aluminum alloy;formation process;quality control;research progress
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发布时间：2023-03-02 - 摘要：Wire arc additive manufacturing (WAAM) technique is applicable to producing large-scale aluminum alloy structures. Recently, lots of efforts have been made to research the WAAM of aluminum alloys. In this paper, a wide range of previous WAAM studies about Al-Cu, Al-Mg, Al-Si, Al-Cu-Mg, Al-Mg-Si, and Al-Zn-Mg-Cu alloys were reviewed and summarized, including the characteristics of the microstructure and properties, forming effects of each series. Based on the characteristics of WAAMed aluminum alloys, common microstructure defects and improvement measures are introduced, such as pore and hot crack in microstructure, and appropriate process parameters and alloy design. This article provides useful ideas for the further development of WAAM technology in aluminum alloys by analyzing the research status of different series aluminum alloys.关键词：WAAM;aluminum alloy;microstructure;mechanical properties
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发布时间：2023-03-02 - 摘要：Metal lattice structure is a kind of lightweight multifunctional structure, which has the advantages of high specific strength, high specific stiffness, anti-explosion, energy absorption, vibration reduction and noise reduction. It has a broad application prospect in aircraft, ships, vehicles, buildings, and other fields. However, up to now, the application scale of lattice structure is still very limited, mainly due to the serious constraints of manufacturing technology. Wire arc additive manufacturing is expected to realize the integrated, efficient, and low-cost manufacturing of complex lattice structures due to its characteristics. This paper comprehensively analyzed the current research situation of metal spatial rod and lattice structure fabricated by wire arc additive manufacturing, discussed the manufacturing principle, forming process, method, manufacturing characteristics and other aspects, and summarizes the research progress and process characteristics of current research institutions for metal lattice based on wire arc additive manufacturing. At last, introduced the limitations of metal lattice structure made by wire arc additive manufacturing. The research progress and deficiency of current wire arc additive manufacturing in lattice manufacturing and forming control are emphatically analyzed, and the main development direction of wire arc additive manufacturing metal lattice structure in the future is proposed.关键词：wire arc additive manufacturing;lattice structure;deposition process;spatial rod structure
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发布时间：2023-03-02 - 摘要：Wire arc additive manufacturing (WAAM) is an effective method for fabricating lattice structure. The WAAM equipment of lattice structure, the design and fabrication technology of Al-based flux-cored wire, the laser constrained arc process and the diameter and angle control method of lattice rod were studied. Typical lattice structure application parts were manufactured. The WAAM equipment of lattice structure is composed of additive manufacturing unit, laser unit and monitoring unit. The Al-Cu-NiO alloy system of in-situ Al2O3 phase Al alloy core wire was designed. The core wire with a diameter of 1.2 mm was prepared, and the deposition rod had low thermal conductivity. Laser excites a large number of neutral particles to ionize, so that the charged particles in the arc greatly increase the arc, which has a restraining and stabilizing effect on the arc and improves the forming accuracy. By controlling the volume and number of droplets in WAAM, lattice unit rods with different diameters of 2.5~7.0 mm can be manufactured. By controlling the lift and offset between the layers of the welding torch during WAAM process, lattice unit rods with different angles of 15°~90° can be prepared. The high-precision forming of planar lattice, cylindrical lattice and curved busbar lattice structures is fabricated by using the lattice structure WAAM technology. The average compressive strength of the lattice structure is 58.53 MPa. The uniform heat source is applied to the upper surface of the lattice test piece. The heat source temperature is 500 ℃. When the heat source is applied for 600 s, the lower surface temperature of the test piece is about 93 ℃, which has high bearing performance and thermal insulation performance.关键词：metal lattice structures;wire arc additive manufacturing;aluminum alloy;equipment;powder core wire
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发布时间：2023-03-02 - 摘要：The double-tungsten TIG arc has low arc pressure characteristics, which can effectively avoid humping and undercutting at high currents and improve the deposition rate. To apply it to additive manufacturing, single wire feeding mode and dual wire feeding mode were used in this paper. For the high-current double-tungsten TIG arc above 200 A, the effects of deposition current, wire feed speed and travel speed on the forming characteristics of the deposition bead are studied. The results show that for the single wire feeding mode, within the range of 200~350 A deposition current, too high wire feeding speed will lead to poor spreading of the deposition bead, while above 350 A, too high wire feed speed will lead to wire insertion defect. For the dual wire feeding mode, the thermal efficiency of the arc melting wire can be improved, effectively reducing the tendency of wire insertion and improving the deposition rate. The maximum permissible wire feed speed for each deposition current from 200 A to 650 A and the travel speed range were finally derived, providing a well-formed process window for double-tungsten TIG arc-based additive manufacturing. The double-tungsten TIG arc-based additive manufacturing can be formed well at 650 A, with a deposition rate of 5.36 kg/h.关键词：double tungsten TIG arc-based additive manufacturing;deposition rate;dual wire;process window
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发布时间：2023-03-02 - 摘要：Multi-wire and multi-arc additive technology has higher molding efficiency. But large heat input will affect the morphology and performance, so the superaudio arc is introduced to refine the grain and improve the penetration depth. In this paper, 316L stainless steel was used as the test material and MIG welding process was adopted to independently build the superaudio triple-wire arc additive manufacturing platform. Based on the single-wire single-channel model, the experiments of triple-wire single-channel single-layer and triple-wire single-channel multi-layer additive process were conducted. The results show that 30 kHz superaudio arc can significantly refine the microstructure of the weld and destroy the dendritic structure, increase the average transverse and horizontal tensile strength by 81 MPa and 23 MPa respectively, increase the average horizontal fracture elongation from 18.5% to 39.3%, and improve the microhardness of the test piece as a whole. But if the frequency is too high, the energy brought by the ultrasonic wave will be too high to slow down the cooling rate, resulting in grain coarsening.关键词：wire arc additive manufacturing;superaudio;multi-wire and multi-arc;microstructure;mechanical properties
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发布时间：2023-03-02 - 摘要：Heat accumulation in wire arc additive manufacturing (WAAM) is easy to cause poor forming quality and low deposition efficiency of parts. Active interpass cooling is beneficial to improve the efficiency of WAAM and improve the forming quality, so it has gained some attention. In this study, based on finite element numerical simulation analysis, the forming process of Ti6Al4V alloy made by WAAM under natural convection cooling and active interpass cooling respectively were simulated. By both experiment and numerical simulation, the effect of active interpass cooling on temperature and thermal stress evolution was investigated for thin-wall structure. The results show that active interpass cooling can increase heat dissipation effectively during deposition and reduce heat accumulation of thin-wall structure, further improve the residual stress in the forming parts and increase the WAAM efficiency.关键词：wire arc additive manufacturing;active interpass cooling;numerical models;temperature field;stress field
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发布时间：2023-03-02 - 摘要：The problems of coarse microstructure and anisotropy arising from the process of wire and arc additive manufacturing (WAAM) of low-carbon high-strength steel have limited the application and development of this technology to a certain extent. In this paper, the introduction of inter-layer ultrasonic impact treatment (UIT) in the WAAM process can effectively improve the microstructure state and anisotropy. The microstructure states of depositions without and with UIT are compared by optical microscope and scanning electron microscope. The results showe that the typical columnar treatment with obvious directionality was transformed into a uniform and fine equiaxed microstructure after UIT. The electron backscatter diffraction results showe that UIT strengthening can substantially improve the microstructure directionality and refine the grains. This is because UIT can break the restriction on dislocation movement within the microstructure and promote dislocation merging and annihilation, which leds to the formation of a large number of substructures and partial recrystallization under the thermal effect of subsequently deposited layers. This transformation hinders the growth of columnar microstructure and divides them into cellular or equiaxed microstructure with small aspect ratios.关键词：wire and arc additive manufacturing;ultrasonic impact treatment;low carbon higt strength steel;microstructure characteristic
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发布时间：2023-03-02 - 摘要：The implementation of wire and arc additive remanufacturing is based on damaged parts' morphology, which usually features space constraints. Planning the motion trajectory of the weld gun not only considers the interference problem but also needs to adapt the deposition gesture to the local morphology of deposition in order to enhance forming quality of beads. In this paper, a deposition trajectory planning method for robotic wire and arc additive remanufacturing is proposed, including the workflow of in-situ repair, an algorithm to calculate weld gun gestures for conformal deposition based on the three-dimensional point cloud of damaged parts, the mechanism for generating motion trajectory of weld gun, and an algorithm for improving weld gun motion stability during deposition. For validation, a damaged part was focused, and the trajectory of repair was generated. The experimental results approve the effectiveness of the proposed algorithms. Compared with other classical algorithms, its shows the superiority of this algorithm in improving the stability of weld gun.关键词：additive remanufacturing;conformal deposition;trajectory planning;stability analysis;filter algorithm
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发布时间：2023-03-02
Wire and Arc Additive Manufacturing
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