CMT电弧增材制造过程传热传质数值模拟

doi:10.3901/JME.2022.01.267

机械工程学报 ›› 2022, Vol. 58 ›› Issue (1): 267-276.doi: 10.3901/JME.2022.01.267

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CMT电弧增材制造过程传热传质数值模拟

赵文勇¹, 曹熙勇², 杜心伟¹, 魏艳红¹, 刘仁培¹, 陈纪城³

1. 南京航空航天大学材料科学与技术学院南京 211106;
2. 南京云岗智能科技有限公司南京 211112;
3. 南京航空航天大学计算机科学与技术学院南京 211106

收稿日期:2021-03-25 修回日期:2021-08-08 出版日期:2022-01-05 发布日期:2022-03-19
通讯作者: 魏艳红(通信作者),女,1965年出生,教授,博士研究生导师。主要研究方向为材料焊接性及焊接工艺、焊接过程数值模拟与仿真、焊接工程应用软件设计、数字化焊接、电弧增材制造。E-mail:yhwei@nuaa.edu.cn
作者简介:赵文勇,男,1994年出生,博士研究生。主要研究方向为焊接及电弧增材制造过程数值模拟。E-mail:wy_zhao@nuaa.edu.cn
基金资助:
江苏高校优势学科建设工程（PAPD）和中国博士后科学基金项目（2020M671479）资助项目。

Numerical Simulation of Heat and Mass Transfer in CMT-based Additive Manufacturing

ZHAO Wenyong¹, CAO Xiyong², DU Xinwei¹, WEI Yanhong¹, LIU Renpei¹, CHEN Jicheng³

1. College of Material Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 211106;
2. Nanjing Yungang Intelligent Technology Co. Ltd, Nanjing 211112;
3. College of Computer Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 211106

Received:2021-03-25 Revised:2021-08-08 Online:2022-01-05 Published:2022-03-19

摘要/Abstract

摘要： 冷金属过渡（Cold metal transfer，CMT）电弧增材制造技术具有熔敷效率高、热输入低、成形稳定等优点，在大尺度构件直接成形领域应用前景广阔。然而，其成形过程熔池热-流等物理场演变机理尚不明确，且很难通过试验手段获得。基于动网格技术，建立了二维CMT电弧增材制造热-流场数值模型。模型中，采用流体体积法追踪金属-气体界面，采用焓-孔隙法处理金属熔化与凝固，采用椭球热源周期性加载等效CMT电弧起收弧过程。基于建立的模型，以铝合金为研究对象，计算分析了不同驱动力对熔池流动行为影响、CMT熔滴过渡过程熔滴与熔池相互作用及不同基板热条件对熔覆层形貌和熔池尺寸的影响。结果表明：Marangoni力对熔池流动行为影响最为剧烈，其次是电弧压力；当熔滴随着焊丝向下运动时，熔滴表面液态金属向下流动，而其内部金属向上流动，形成环流；当熔滴进入熔池后，熔池表面金属向两侧边缘铺展，并在底部形成两股反向涡流；随着基板温度的升高，熔覆层形貌从瘦高状向扁平状转变。

关键词: 冷金属过渡, 电弧增材制造, 温度场, 流场, 熔池, 数值模拟

Abstract: Cold metal transfer (CMT)-based wire arc additive manufacturing(WAAM) technology has a broad application prospect in the direct forming of large-scale components due to the advantages of high melting efficiency, low heat input and stable forming shape. However, the physical field evolution mechanism of molten pool is not clear, and it is difficult to obtain by trial-and-error method. A two-dimensional heat transfer and fluid flow model of CMT-based WAAM is developed basing on dynamic meshing technical. The volume of fluid (VOF) method is used to track the metal-gas interface, the enthalpy-porosity method is employed to handle metal melting and solidification, and the periodic loading ellipsoid heat source is selected to describe the stage of arc combustion and extinguishing. By the developed model, the deposition process of aluminum alloy CMT-based WAAM is simulated, and the influence of various driving forces on the flow behavior of molten pool, the interaction between droplet and molten pool during CMT droplet transition and the influence of different substrate thermal conditions on the deposits shape are investigated. The results show that the Marangoni force is dominant to drive the fluid flow of molten pool, and followed by the arc pressure. When the droplet moves downward with the wire, liquid metal on the surface of droplet flows downward, while the metal inside flows upward to form a circulation. When the droplet enters the molten pool, the liquid metal on the free surface of molten pool flows to periphery of both sides, and two reverse vortexes are formed at the bottom of the molten pool. In addition, with the increase of substrate temperature, the deposition morphology changes from thin to flat.

Key words: clod metal transfer, wire arc additive manufacturing, temperature field, fluid field, molten pool, numerical simulation

中图分类号:

TG442

赵文勇, 曹熙勇, 杜心伟, 魏艳红, 刘仁培, 陈纪城. 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 Wenyong, CAO Xiyong, DU Xinwei, WEI Yanhong, LIU Renpei, CHEN Jicheng. Numerical Simulation of Heat and Mass Transfer in CMT-based Additive Manufacturing[J]. Journal of Mechanical Engineering, 2022, 58(1): 267-276.

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CMT电弧增材制造过程传热传质数值模拟

Numerical Simulation of Heat and Mass Transfer in CMT-based Additive Manufacturing

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