基于Al和NiO的冶金反应设计了圆柱面点阵电弧增材制造自生Al₂O₃铝合金粉芯丝材，进行了热分析；制备了直径1.2 mm的自生Al₂O₃铝合金粉芯丝材，研究了其工艺性能，分析了自生Al₂O₃的尺寸、形貌，并测试了单元杆的热导率和强度；利用该粉芯丝材在直径157 mm的圆柱面上成形了两层金字塔点阵结构。结果表明：Al和NiO冶金反应的最大反应速率温度为1 038.9 ℃，能够在电弧增材制造条件下可靠进行；粉芯中含1.5%NiO的铝合金粉芯丝材在电弧增材制造中电弧稳定、熔滴呈均匀小颗粒过渡、过程平稳、飞溅率小于0.74%。研发的粉芯丝材成形点阵单元杆表面粗糙度小于10.40 μm，自生成了大量的密排六方α-Al₂O₃，尺寸在50~300 nm之间，与铝基体的界面结合良好；单元杆的热导率为103.68 W/（m·K），平均抗拉强度达到了288 MPa；成形的圆柱面点阵单元杆直径误差在±0.1 mm以内，倾角误差在±0.9°以内，具有较高的精度。在隔热实验中点阵测试件上下表面的温差超过400 ℃，具有良好的隔热性能。点阵测试件的抗压强度约65 MPa，压缩性能较稳定。

Based on the metallurgical reaction of Al and NiO， an in-situ Al₂O₃ aluminum alloy powder core wire for cylindrical lattice wire arc additive manufacturing is designed， followed by its thermal analysis. The in-situ Al₂O₃ aluminum alloy powder core wire with a diameter of 1.2 mm is prepared， its process performance is studied， the size and morphology of the in-situ Al₂O₃ are analyzed， and the thermal conductivity and strength of the unit rod are tested. The powder core wire is used to form a double-layer pyramid lattice structure on a cylindrical surface with a diameter of 157 mm. The results show that the maximum reaction rate temperature of the metallurgical reaction of Al and NiO is 1 038.9 ℃， which can be carried out reliably under the conditions of wire arc additive manufacturing. The aluminum alloy powder core wire with 1.5% NiO has stable arc， uniform small particle transition， stable process， and spatter rate of less than 0.74% in wire arc additive manufacturing. The surface roughness of the unit rod formed by the powder core wire is less than 10.40 μm， and a large amount of close-packed hexagonal α-Al₂O₃ is generated in situ with the size between 50-300 nm， and the interface with the aluminum matrix is well bonded. The thermal conductivity of the unit rod is 103.68 W/（m·K）， and the average tensile strength reaches 288 MPa. The diameter error of the formed cylindrical lattice unit rod is within ±0.1 mm， and the inclination error is within ±0.9°， which has high accuracy. In the heat insulation experiment， the temperature difference between the upper and lower surfaces of the lattice test piece is more than 400 ℃， which has good heat insulation performance. The compressive strength of the lattice test piece is about 65 MPa， and the compression performance is stable.