ACTA AERONAUTICAET ASTRONAUTICA SINICA >
Influence of droplet transition mode on deposition morphology in droplet-arc hybrid additive manufacturing
Received date: 2024-12-25
Revised date: 2025-01-20
Accepted date: 2025-03-24
Online published: 2025-04-10
Supported by
National Natural Science Foundation of China(52465048);Aeronautical Science Foundation of China(20200054070001);Natural Science Foundation of Ningxia Hui Autonomus Region, China(2024AAC03055)
The interaction of the tilted Tungsten Inert Gas （TIG） welding arc and the continuously controllable droplets is a complex phenomenon， which determines the surface morphology of deposited layers， the microstructure and internal defects of fabricated parts in droplet-arc hybrid additive manufacturing. To reveal the influence law of the droplet transfer mode on the deposition morphology， a three-dimensional numerical model based on Computational Fluid Dynamics （CFD） was developed to investigate the molten pool behaviors during droplet-arc hybrid additive manufacturing. Deposition experiments were conducted to verify and calibrate the numerical model. The process of drop impact， spreading， retraction and solidification is illustrated and analyzed using calculated results. The results show that when droplet transfer mode changes from low-frequency large droplet to high-frequency small droplet， the coalescence behavior between the droplet and the TIG arc molten pool shifts from partial coalescence to complete coalescence. As a result， the “fish scale” pattern characteristic on the surface of the deposited layer is significantly reduced. This study provides a perspective in understanding the physical phenomena involved in droplet-arc hybrid additive manufacturing and lays the foundation for the optimization of process parameters.
Jun DU , Ao CUI , Zhiqiang LI , Zhihao WAN . Influence of droplet transition mode on deposition morphology in droplet-arc hybrid additive manufacturing[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2025 , 46(17) : 431710 -431710 . DOI: 10.7527/S1000-6893.2024.31710
| [1] | DEBROY T， WEI H L， ZUBACK J S， et al. Additive manufacturing of metallic components—Process， structure and properties［J］. Progress in Materials Science， 2018， 92： 112-224. |
| [2] | KOLADE O， OWOSENI A. Employment 5.0： The work of the future and the future of work［J］. Technology in Society， 2022， 71： 102086. |
| [3] | 刘壮壮， 丁明路， 谢建新. 金属3D打印数字化制造研究进展［J］. 金属学报， 2024， 60（5）： 569-584. |
| LIU Z Z， DING M L， XIE J X. Advancements in digital manufacturing for metal 3D printing［J］. Acta Metallurgica Sinica， 2024， 60（5）： 569-584 （in Chinese）. | |
| [4] | 张百成， 张文龙， 曲选辉. 基于高通量制备的增材制造材料成分设计［J］. 金属学报， 2023， 59（1）： 75-86. |
| ZHANG B C， ZHANG W L， QU X H. Composition design of additive manufacturing materials based on high throughput preparation［J］. Acta Metallurgica Sinica， 2023， 59（1）： 75-86 （in Chinese）. | |
| [5] | 周燕， 文世峰， 魏青松， 等. 增材制造专用模具钢粉末材料设计、制备及其制造技术［J］. 中国材料进展， 2020， 39（5）： 356-363. |
| ZHOU Y， WEN S F， WEI Q S， et al. Design， preparation and manufacturing technology of special mold steel powder materials for additive manufacturing［J］. Materials China， 2020， 39（5）： 356-363 （in Chinese）. | |
| [6] | 左寒松， 李贺军， 齐乐华， 等. 铝合金微熔滴沉积成形过程中缺陷形成机理研究［J］. 稀有金属材料与工程， 2013， 42（8）： 1596-1600. |
| ZUO H S， LI H J， QI L H， et al. Formation mechanism of defects in aluminum alloy during micro-droplet deposition［J］. Rare Metal Materials and Engineering， 2013， 42（8）： 1596-1600 （in Chinese）. | |
| [7] | LIU M L， YI H， CAO H J， et al. Heat accumulation effect in metal droplet-based 3D printing： Evolution mechanism and elimination strategy［J］. Additive Manufacturing， 2021， 48： 102413. |
| [8] | DOU Y B， LUO J， QI L H， et al. Quantitatively characterizing the evolution of hole defects between overlapped aluminum droplets by a two-dimensional solidification model［J］. Additive Manufacturing， 2022， 60： 103202. |
| [9] | 杜军， 吴云肖， 蒋敏博， 等. TIG电弧辅助熔滴沉积增材制造SiCp增强铝基复合材料中的熔池动力学与颗粒迁移行为［J］. 机械工程学报， 2023， 59（3）： 318-327. |
| DU J， WU Y X， JIANG M B， et al. Molten pool dynamics and particle migration behavior during TIG-assisted droplet deposition manufacturing of SiC particle-reinforced aluminum matrix composites［J］. Journal of Mechanical Engineering， 2023， 59（3）： 318-327 （in Chinese）. | |
| [10] | DU J， WANG D Q， XU S Y. Gas tungsten arc welding assisted droplet deposition manufacturing of steel/lead bimetallic structures［J］. Journal of Materials Processing Technology， 2021， 292： 117069. |
| [11] | 廉艳平， 王潘丁， 高杰， 等. 金属增材制造若干关键力学问题研究进展［J］. 力学进展， 2021， 51（3）： 648-701. |
| LIAN Y P， WANG P D， GAO J， et al. Fundamental mechanics problems in metal additive manufacturing： A state-of-art review［J］. Advances in Mechanics， 2021， 51（3）： 648-701 （in Chinese）. | |
| [12] | 欧文敏. MIG电弧增材制造过程数值模拟及成形均匀性调控研究［D］. 南京： 南京航空航天大学， 2020. |
| OU W M. Numerical simulation of deposit morphology and uniformity regulation research during MIG wire arc additive manufacturing［D］. Nanjing： Nanjing University of Aeronautics and Astronautics， 2020 （in Chinese）. | |
| [13] | 赵文勇， 曹熙勇， 杜心伟， 等. CMT电弧增材制造过程传热传质数值模拟［J］. 机械工程学报， 2022， 58（1）： 267-276. |
| ZHAO W Y， CAO X Y， DU X W， et al. Numerical simulation of heat and mass transfer in CMT-based additive manufacturing［J］. Journal of Mechanical Engineering， 2022， 58（1）： 267-276 （in Chinese）. | |
| [14] | CHEN X， WANG C， DING J L， et al. A three-dimensional wire-feeding model for heat and metal transfer， fluid flow， and bead shape in wire plasma arc additive manufacturing［J］. Journal of Manufacturing Processes， 2022， 83： 300-312. |
| [15] | CADIOU S， COURTOIS M， CARIN M， et al. 3D heat transfer， fluid flow and electromagnetic model for cold metal transfer wire arc additive manufacturing （Cmt-Waam）［J］. Additive Manufacturing， 2020， 36： 101541. |
| [16] | YI H， JIAO F R， CAO H J， et al. Numerical simulations of molten pool dynamics in wire-arc directed energy deposition processes： A review［J］. Journal of Manufacturing Processes， 2025， 134： 970-997. |
| [17] | CHO D W， NA S J， CHO M H， et al. A study on V-groove GMAW for various welding positions［J］. Journal of Materials Processing Technology， 2013， 213（9）： 1640-1652. |
| [18] | NASIRI M B， BEHZADINEJAD M， LATIFI H， et al. Investigation on the influence of various welding parameters on the arc thermal efficiency of the GTAW process by calorimetric method［J］. Journal of Mechanical Science and Technology， 2014， 28（8）： 3255-3261. |
/
| 〈 |
|
〉 |
CJA