金属激光增材+X复合制造技术综述

doi:10.7527/S1000-6893.2023.29349

Abstract

Abstract:

Laser Additive Manufacturing （LAM） provides a high degree of design freedom and manufacturing flexibility for the preparation of complex metal parts in aerospace engineering， but current mainstream LAM technologies have key problems such as difficulty in monitoring and control， thermal stress deformation， and defects management. while additive manufacturing + X hybrid technology provide multi-scale solutions， and by combining the advantages of various auxiliary manufacturing processes， the accuracy and performance of AM forming materials are improved. AM + mechanical/magnetic/acoustic/thermal field enable achieve synergistic optimization of beneficial effects such as controlling melt pool flow， improving microstructure， management grain size orientation， releasing residual stress， and improving surface quality. The development of mainstream LAM technology and the current application status in the aerospace industry are reviewed， the action mechanism of additive-subtractive and additive-equivalent hybrid manufacturing technologies on LAM are summarized， and the mechanism and simulation research of non-contact magnetic， acoustic， and thermal auxiliary fields on melt pool dynamics， microstructure development， surface quality development， thermal gradient are emphatically commented. In conclusion， the strengths and limitations of various field auxiliary additive manufacturing technologies are summarized， and the future trends of laser-metal additive manufacturing + X hybrid technology are anticipated.

Key words: laser additive manufacturing, hybrid manufacturing, metal forming, auxiliary field, additive+X

CLC Number:

Yi LI, Zhenzhong WANG, Yuhang XIAO, Pengfei ZHANG. Review of laser⁃metal additive manufacturing + X hybrid technology[J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(13): 629349-629349.

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Table 2

A summary of the principle， advantages and disadvantages， and main references of the “Additive manufacturing + X” technology

增材+X	技术原理	优点	缺点	主要文献
增材+磁场	主要通过调控熔池流动以改善微观组织；磁场诱导的热电磁对流抑制熔池内的马朗戈尼对流，降低熔池速度，改善熔池温度梯度；破坏枝晶，增加形核位点。	减少孔隙率和开裂；改善熔池热量分布；调控熔池几何形状；提高表面粗糙度；影响微观组织；调整晶粒形态/尺寸。	磁场设置不合理将影响表面粗糙度；大部分增材材料为顺磁性材料和抗磁性材料，磁场应用范围有限。	［63， 67， 78-81， 93， 94， 97， 113］
增材+声场	主要影响熔池动力学以改善微观组织。超声诱导的声流和空化效应搅动熔池流动，降低温度梯度，释放气泡；破坏枝晶。	细化晶粒；促进元素均匀分布；缓解机械各向异性；提高强度和延展性。	降低成形材料表面粗糙度；超声振动发生器需要与基板接触，干涉加工。	［58， 64， 71， 90， 99］
增材+热场	主要影响增材过程中的温度场。输入能量决定熔池的形状、大小和冷却速率，导致熔池的传热状态不同，调控材料的微观组织。	提高工艺稳定性；增加沉积速率；改善表面质量；提高致密度；减少残余应力和变形开裂风险；改善微观组织；提高力学性能。	热送丝、基板加热等需额外设备，设备隔热要求高；层间激光重熔、激光冲击强化等影响加工效率。	［65， 72， 73， 84， 86， 106-108， 110］
增材+机械场	主要通过在加工表面施加塑性变形改善材料致密度以及力学性能。工件塑性变形导致材料再结晶，形成更多的位错和形核位点；释放增材成形材料中的残余应力。	诱发塑性变形；动态再结晶；释放残余应力；细化晶粒；提高致密度。	需要与材料进行接触，易产生干涉问题，影响加工效率。	［54， 55， 57-59， 119］

Table 2

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增材工艺	材料添加方式	原料尺寸	优势	劣势	应用实例	文献
激光粉末床熔融技术	粉末	10~45 μm	高准确性和精度	需要支撑结构	涡轮叶片复杂发动机零部件卫星组件 …	［7-8， 18-20］
			高致密性	高残余应力
			高特异强度和刚度	机械各向异性
			粉末可回收	尺寸限制
激光定向能量沉积技术	粉末	45~155 μm	高灵活性	存在孔隙等缺陷	翼肋法兰加强板 …	［7-8， 19-20］
			制备功能梯度材料	残余应力
			开发合金	低精度
	丝材	0.6~1.6 mm	低成本	成型表面粗糙
			零件修复/再制造	打印复杂形状的局限性
			低损耗	高控制要求
			加工时间短	需要后处理

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[3]	GU Dongdong, ZHANG Han, LIU Gang, YANG Biqi. Process optimization of additive manufactured sandwich panel structure using rare earth element modified high-performance Al alloy [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2021, 42(10): 524868-524868.
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[5]	WANG Huaming. Materials’ Fundamental Issues of Laser Additive Manufacturing for High-performance Large Metallic Components [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2014, 35(10): 2690-2698.
[6]	Zheng Mao-sheng;Luo Zi-jian;Zheng Xiu-lin. DAMAGE MECHANICS FOR ORTHOGONAL ANISOTROPIC DUCTILE MATERIALS [J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 1993, 14(1): 56-62.

Review of laser⁃metal additive manufacturing + X hybrid technology

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