
摆弧工艺对丝-弧增材制造Al5356直壁构件成形质量和组织性能的影响
王晋, 孙高明, 杨全涛, 史秋月, 孙建新, 张元好
摆弧工艺对丝-弧增材制造Al5356直壁构件成形质量和组织性能的影响
Effect of swing arc process on forming quality,microstructure and mechanical properties of Al5356 straight-wall components manufactured by wire-arc additive manufacturing
在丝-弧增材制造过程中对焊枪施加不同频率和摆幅的侧向摆动,制备Al5356直壁构件。通过表面波纹度计算、微观组织分析和拉伸性能测试,研究了摆弧参数对Al5356直壁构件成形质量、孔隙分布、显微组织和力学性能的影响规律。研究发现,在丝-弧增材制造中应用摆弧工艺能够显著改善直壁样品的成形精度,减少孔隙缺陷,均匀化组织及提升样品的力学性能。在实验参数范围内,与无摆弧工艺相比,施加摆弧工艺可将Al5356直壁样品的表面波纹度减小60%,孔隙率和最大孔隙直径从超过0.65%和33 µm分别降至0.20%和10 µm以下,X方向(沉积方向)和Z方向(构建方向)的平均抗拉强度分别提升了约13%和15%,而平均伸长率分别提高了约27%和25%。电弧摆动频率比摆幅对提高沉积构件表面质量、分散孔隙、减小孔隙尺寸具有更显著的效果,这是由于高频率的电弧振荡对熔池具有强烈搅拌作用,使沉积焊道横向的温度更均匀。沉积构件力学性能的提升主要归因于孔隙缺陷的减少和微观组织的均匀化。在丝-弧增材制造中正确应用摆弧工艺对提升构件的成形质量和力学性能有积极意义。
During the wire-arc additive manufacturing process, Al5356 straight-wall components are fabricated by imparting lateral swings of varying frequencies and amplitudes to the welding gun. The impact of these swinging arcs on the forming quality, pore distribution, microstructure, and mechanical properties of the components is evaluated through surface waviness calculations, microstructural analysis, and mechanical tensile tests. The results show that incorporating the arc swing technique in the manufacturing process significantly enhances the forming accuracy, compactness, microstructural uniformity, and mechanical properties of the straight-wall samples. Within the experimental parameters, applying an arc swing reduces the surface waviness of Al5356 straight-wall samples by 60% compared to those produced without an arc swing. Additionally, the porosity and maximum pore diameter are decreased from over 0.65% and 33 µm to below 0.20% and 10 µm, respectively. The average tensile strength in both the X-direction (deposition direction) and Z-direction (build direction) increases by approximately 13% and 15%, respectively, while the average elongation improves by about 27% and 25%, respectively. Notably, the frequency of the arc swing has a more pronounced effect than the amplitude in enhancing surface quality, pore dispersion, and pore diameter reduction in the deposited components. High-frequency arc oscillation exerts a potent stirring effect on the melt pool, leading to a more uniform temperature distribution across the transverse direction of the deposited weld path. The observed enhancement in mechanical properties is primarily attributed to the reduction of pore defects and the homogenization of the microstructure. Therefore, the proper application of the arc swing technique in wire-arc additive manufacturing holds significant promise for improving the forming quality and mechanical properties of components.
丝-弧增材制造 / 铝合金 / 孔隙率 / 成形质量 / 显微组织 / 力学性能
wire-arc additive manufacturing / aluminium alloy / porosity / forming quality / microstructure / mechanical property
TG44 / TB31
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