电弧填丝增材制造过程熔滴射滴过渡特征及其对熔滴沉积成形的影响
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摘要
基于脉冲GMA电弧检测了电弧填丝增材制造过程中与熔滴过渡相关的电弧电流、电弧电压和声发射信号,研究了电弧脉冲作用下的铝合金熔滴射滴过渡特征,提出了一种可对处于射滴过渡模式下的熔滴尺寸、电弧力和熔滴沉积率进行计算的方法,并分析了沉积层的成形质量特征。研究结果表明,利用检测获得的电弧电压、电弧电流信号和声发射信号可以对处于射滴过渡模式下的熔滴过渡过程及其特征进行区分。在本研究条件下,作用在过渡熔滴上的电弧力随电弧功率增加而递增。电弧力的增加将限制熔滴尺寸的增大,从而在电弧功率递增时呈现熔滴尺寸的递减和熔滴过渡频率的递增。同时,电弧功率增加,使热输入增大,射滴过渡熔滴对熔池的冲击增强,容易造成熔滴过渡形成的沉积层坍塌,从而使熔滴沉积层高度递增的趋势减缓,形成的沉积层显微组织明显粗化。
The arc current, voltage and acoustic emission signals related to the metal droplet transfer are detected in real-time during the wire + arc additive manufacturing process, and are studied to analyze the characteristics of metal droplet transferred by projected transfer mode in DC-pulsed arc. Accordingly, a method is presented to calculate the size of droplet, arc force and droplet deposition rate in the projected transfer mode. Furthermore, the forming quality characteristics of the deposition layer are analyzed. The results show that the arc voltage, the arc current and the acoustic emission signals can be used to distinguish the droplet transfer process and the characteristics of the droplet transfer. Under the conditions of this study, the arc force increases with the increase of the arc power.The increase of the arc force will restrict the increase of the droplet size, so that the droplet size decreases and the droplet transfer frequency increases with the increase of arc power. At the same time, the increase of arc power improves the heat input and the force of spray droplet acting on the molten pool. Therefore, it is easy to cause the collapse of deposition layer, the trend of the height increasing of the deposition layer is slowed down and the microstructure of the deposition layer is obviously coarsened.
The arc current, voltage and acoustic emission signals related to the metal droplet transfer are detected in real-time during the wire + arc additive manufacturing process, and are studied to analyze the characteristics of metal droplet transferred by projected transfer mode in DC-pulsed arc. Accordingly, a method is presented to calculate the size of droplet, arc force and droplet deposition rate in the projected transfer mode. Furthermore, the forming quality characteristics of the deposition layer are analyzed. The results show that the arc voltage, the arc current and the acoustic emission signals can be used to distinguish the droplet transfer process and the characteristics of the droplet transfer. Under the conditions of this study, the arc force increases with the increase of the arc power.The increase of the arc force will restrict the increase of the droplet size, so that the droplet size decreases and the droplet transfer frequency increases with the increase of arc power. At the same time, the increase of arc power improves the heat input and the force of spray droplet acting on the molten pool. Therefore, it is easy to cause the collapse of deposition layer, the trend of the height increasing of the deposition layer is slowed down and the microstructure of the deposition layer is obviously coarsened.
引文
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[2]DING D H,PAN Z X,CUIURI D,et al.A multi-bead overlapping model for robotic wire and arc additive manufacturing(WAAM)[J].Robotics and ComputerIntegrated Manufacturing,2015,31:101-110.
[3]YANG D Q,HE C J,ZHANG G J.Forming characteristics of thin-wall steel parts by double electrode GMAW based additive manufacturing[J].Journal of Materials Processing Technology,2016,227:153-160.
[4]TAKEYUK A,HIROYUKI S.Dissimilar metal deposition with a stainless steel and nickel-based alloy using wire and arc-based additive manufacturing[J].Precision Engineering,2016,45:387-395.
[5]WANG J F,SUN Q J,WANG H,et al.Effect of location on microstructure and mechanical properties of additive layer manufactured Inconel 625 using gas tungsten arc welding[J].Materials Science&Engineering A,2016,676:395-405.
[6]MA Y,CUIURI D,SHEN Chen,et al.Effect of interpass temperature on in-situ alloying and additive manufacturing of titanium aluminides using gas tungsten arc welding[J].Additive Manufacturing,2015,8:71-77.
[7]JHAVAR S,JAIN N K,PAUL C P.Development of micro-plasma transferred arc(u-PTA)wire deposition process for additive layer manufacturing applications[J].Journal of Materials Processing Technology,2014,214:1102-1110.
[8]ZHANG J K,WANG X Y,PADDEA S,et al.Fatigue crack propagation behaviour in wire+arc additive manufactured Ti-6Al-4V:Effects of microstructure and residual stress[J].Materials and Design,2016,90:551-561.
[9]XIONG J,YIN Z Q,ZHANG W H.Closed-loop control of variable layer width for thin-walled parts inwire and arc additive manufacturing[J].Journal of Materials Processing Technology,2016,233:100-106.
[10]刘一搏,孙清洁,姜云禄,等.基于冷金属过渡技术快速成形工艺[J].焊接学报,2014,35(7):1-4.LIU Yibo,SUN Qingjie,JIANG Yunlu,et al.Rapid prototyping process based on cold metal transfer arc welding technology[J].Transactions of The China Welding Institution,2014,35(7):1-4.
[11]从保强,丁佳洛.CMT工艺对Al-Cu合金电弧增材制造气孔的影响[J].稀有金属材料与工程,2014,43(12):3149-3153.CONG Baoqiang,DING Jialuo.Influence of CMTprocess on porosity of wire arc additive manufactured Al-Cu alloy[J].Rare Metal Materials and Engineering,2014,43(12):3149-3153.
[12]柏久阳,王计辉,林三宝,等.铝合金电弧增材制造焊道宽度尺寸预测[J].焊接学报,2015,36(9):87-90.BAI Jiuyang,WANG Jihui,LIN Sanbao,et al.Width prediction of aluminium alloy weld additively manufactured by TIG arc[J].Transactions of The China Welding Institution,2015,36(9):87-90.
[13]申俊琦,胡绳荪,刘望兰,等.铝合金焊接快速成形层间间隔时间分析[J].焊接学报,2008,29(5):109-112.SHEN Junqi,HU Shengsun,LIU Wanglan,et al.Effects of time interval in rapid prototyping of Al-alloy based on welding[J].Transactions of The China Welding Institution,2008,29(5):109-112.
[14]乌日开西·艾依提,赵万华,买买提明·艾尼,等.基于等离子弧焊的Ti-6Al-4V快速成形工艺参数研究[J].稀有金属材料与工程,2012,41(1):134-138.WURIKAIXI Aiyiti,ZHAO Wanhua,MAMTIMIN Geni,et al.Study on the processing parameters of plasma arc welding-based rapid prototyping for Ti-6Al-4V alloy parts[J].Rare Metal Materials and Engineering,2012,41(1):134-138.
[15]徐富家,吕耀辉,刘玉欣,等.脉冲PAW快速成形焊缝尺寸的预测模型[J].焊接学报,2012,33(1):49-52.XU Fujia,LüYaohui,LIU Yuxin,et al.Prediction model of bead geometry shaped by rapid prototyping based on pulsed PAW[J].Transactions of The China Welding Institution,2012,33(1):49-52.
[16]符卫,胡绳荪,尹玉环.熔滴过渡对脉冲熔化极氩弧焊快速成形的影响[J].机械工程学报,2009,45(4):95-99.FU Wei,HU Shengsun,YIN Yuhuan.Effect of droplet transition on rapid prototyping by P-MIG[J].Journal of Mechanical Engineering,2009,45(4):95-99.