电弧熔丝增材制造传热传质数值模拟研究现状与展望

doi:10.3901/JME.2024.08.065

机械工程学报 ›› 2024, Vol. 60 ›› Issue (8): 65-80.doi: 10.3901/JME.2024.08.065

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电弧熔丝增材制造传热传质数值模拟研究现状与展望

张云舒¹, 吴斌涛¹, 赵昀², 丁东红³, 潘增喜⁴, 李会军⁴

1. 宁夏大学材料与新能源学院银川 750021;
2. 江苏自动化研究所连云港 222006;
3. 南京工业大学机械与动力工程学院南京 211816;
4. 伍伦贡大学机械、材料、机电与生物工程学院伍伦贡 2522 澳大利亚

收稿日期:2023-03-09 修回日期:2023-10-09 出版日期:2024-04-20 发布日期:2024-06-17
作者简介:张云舒,男,1998年出生。主要研究方向为电弧熔丝增材制造传热传质数值模拟。E-mail:1597410698@qq.com;吴斌涛(通信作者),男,1990年出生,博士,副教授,硕士研究生导师。主要研究方向为大型金属增材制造智能装备设计与工艺研发,产品质量检测与评价、工艺规范设计等。E-mail:wubintao@outlook.com
基金资助:
宁夏自然科学基金(重点)资助项目(2021AAC02001)。

Research Progress in the Numerical Simulation of Heat and Mass Transfer during Wire Arc Additive Manufacturing

ZHANG Yunshu¹, WU Bintao¹, ZHAO Yun², DING Donghong³, PAN Zengxi⁴, LI Huijun⁴

1. School of Materials and New Energy, Ningxia University, Yinchuan 750021;
2. Jiangsu Automation Research and Institute, Lianyungang 222006;
3. School of Mechanical and Power Engineering, Nanjing Tech University, Nanjing 211816;
4. School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong 2522 Australia

Received:2023-03-09 Revised:2023-10-09 Online:2024-04-20 Published:2024-06-17

摘要/Abstract

摘要： 电弧熔丝增材制造具有设备成本低、制造效率高等特点，在航空航天、舰船、武器装备等领域具备广阔的应用前景。在复杂热循环的条件下，电弧行为、熔滴过渡、熔池流动与凝固以及沉积内部热积累效应等因素的耦合作用是决定结构成形与质量的关键，也是实现控形控性的理论基础。基于电弧熔丝增材制造的物理过程数值模拟研究现状，综述了不同热源类型电弧增材制造工艺过程中的物理机制，揭示了不同沉积过程传热传质行为的内在关联与区别。在此基础上，概述了常见形貌缺陷的形成机理、影响因素与其抑制策略，总结了不同主动控热控形控性方法的机制与特点，探讨了当前电弧熔丝增材制造传热传质数值模拟过程中存在的主要问题，并对其未来发展应用提出了思考与建议。

关键词: 电弧熔丝增材制造, 数值模型, 传热传质, 形貌缺陷, 控热控形控性

Abstract: Wire Arc Additive Manufacturing (WAAM), which is able to create large metal components with high deposition rate and low equipment cost, has increasingly attracted attention from industrial sectors, including aerospace, shipbuilding, military equipment etc. During WAAM, the combined effects from arc characteristics, droplet transfer behaviour, molten pool flow and solidification, and heat accumulation under the complex thermal cycle plays a critical role in the deposition formation and quality, which also the theoretical basis of realizing the geometry and material properties in control. The emerging research on the numerical simulation of WAAM is reviewed in this article, and a comprehensive overview of the physical mechanism of WAAM based on different heat sources is also provided. The heat and mass transfer produced in different WAAM process are described to reveal their intrinsic connections. Common defects are depicted, including formation mechanism, inside factors, inhibition strategy. Methods for controlling the deposition process, geometry and quality are discussed, take into account the physical characteristics of WAAM. It is concluded in this paper that many challenges still exist in the numerical simulation of the WAAM process, and critical thinking and suggestions are proposed for its future development and application.

Key words: wire arc additive manufacturing, numerical model, heat and mass transfer, defect, quality control

中图分类号:

TG156

张云舒, 吴斌涛, 赵昀, 丁东红, 潘增喜, 李会军. 电弧熔丝增材制造传热传质数值模拟研究现状与展望[J]. 机械工程学报, 2024, 60(8): 65-80.

ZHANG Yunshu, WU Bintao, ZHAO Yun, DING Donghong, PAN Zengxi, LI Huijun. Research Progress in the Numerical Simulation of Heat and Mass Transfer during Wire Arc Additive Manufacturing[J]. Journal of Mechanical Engineering, 2024, 60(8): 65-80.

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电弧熔丝增材制造传热传质数值模拟研究现状与展望

Research Progress in the Numerical Simulation of Heat and Mass Transfer during Wire Arc Additive Manufacturing

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