基于一体化模型的铝合金MIG增材单道形貌、传热及流动行为研究

doi:10.3901/JME.2025.22.097

机械工程学报 ›› 2025, Vol. 61 ›› Issue (22): 97-108.doi: 10.3901/JME.2025.22.097

• 材料科学与工程 • 上一篇

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基于一体化模型的铝合金MIG增材单道形貌、传热及流动行为研究

赵文勇¹, 魏艳红², 胥国祥¹, 胡庆贤¹, 王耀伟¹

1. 江苏科技大学材料科学与工程学院镇江 212114;
2. 南京航空航天大学材料科学与技术学院南京 211106

收稿日期:2024-11-20 修回日期:2025-05-09 发布日期:2026-01-10
作者简介:赵文勇,男,1994年出生,博士,讲师。主要研究方向为大型复杂结构应力变形与控制,焊接及增材制造过程传热流动行为数值分析。E-mail:zhaowy_nh@126.com
胥国祥(通信作者),男,1981年出生,博士,教授,博士研究生导师。主要研究方向为激光-电弧复合焊、摇动电弧窄间隙GMAW焊等先进焊接工艺机理及焊接过程数值模拟。E-mail:xugxiang@163.com
基金资助:
国家自然科学基金资助项目(52405366,51975263,52375340)。

Research on the Morphology, Heat Transfer, and Metal Flow Behavior of MIG-based Wire Arc Additively Manufactured Single-pass Aluminum Alloy via Integrated Model

ZHAO Wenyong¹, WEI Yanhong², XU Guoxiang¹, HU Qingxian¹, WANG Yaowei¹

1. School of Materials Science and Engineering, Jiangsu University of Science and Technology, Zhenjiang 212114;
2. College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 211106

Received:2024-11-20 Revised:2025-05-09 Published:2026-01-10

摘要/Abstract

摘要： 深入理解工艺参数条件与复杂物理现象及成形质量之间的内在影响机理是获得结构合理、性能可靠、无缺陷的高质量电弧增材构件的重要前提。本研究综合考虑电弧传热、熔滴过渡、金属蒸发、熔池自由表面变形、熔池金属对流、金属熔化与凝固及焊枪与基板相对移动等多物理过程，构建铝合金电弧增材制造电弧-熔滴-熔池一体化三维瞬态数值模型。模型中，采用流体体积分数法追踪气液自由界面，基于“局部热力学平衡-扩散近似”模型考虑鞘层复杂热效应，采用移动参考系处理焊枪与基板的相对运动，并从熔滴过渡及熔覆层形貌两方面验证了模型的准确性。基于建立的模型，模拟分析焊接电流和熔覆速度对铝合金电弧增材单道成形形貌演变、液态金属传热和流体动力学行为的影响机理。结果表明：随着焊接电流的增加，熔覆层截面形貌由圆弧状向扁平状转变，熔池金属温度梯度和流速升高，但流动类型变化较小；随着熔覆速度的增加，熔覆层截面形貌由扁平状向圆弧状转变，熔池深度和内部金属温度梯度降低，同时液态金属整体向熔池后方流动的流动行为转变加快。

关键词: 电弧增材制造, 数值模拟, 多物理场耦合, 传热流动

Abstract: An in-depth understanding of the inherent influence mechanism between process parameters, complex physical phenomena and forming quality is an important prerequisite for obtaining high-quality arc additively manufactured parts with reasonable structure, reliable performance and no defects. In this paper, a 3D arc plasma-droplet-molten pool integrated transient model of wire arc additive manufacturing of aluminum alloy is developed, which simultaneously considers the heating of arc plasma, droplet transfer, the vaporization of metal, the deformation of molten pool free surface, the convection of molten pool metal, the melting and solidification of metal, and the relative movement between wire and substrate. In this model, the volume of fluid（VOF） method is used to track the gas-liquid free interface, the complex thermal effect of the sheath is considered based on the “local thermodynamic equilibrium（LTE）-diffusion approximation” model, and the moving reference frame is utilized to handle the relative motion between the wire and the substrate. The accuracy of the integrated model was verified by the experimentally measured droplet transfer and deposited layer profile. Based on the established model, the influence mechanisms of welding current and travel speed on the deposited layer morphology evolution and the metal heat transfer and fluid flow behavior were analyzed. The results show that with the increase of welding current, the cross-section of deposited layer changes from arc-shaped to flattened, the temperature gradient and the flow rate of the molten pool metal increase, but the change in flow pattern is relatively small. With the increase of travel speed, the cross-section of deposited layer changes from flattened to arc-shaped, the depth and the metal temperature gradient of the molten pool decrease, and the flow behavior transition of the molten metal as a whole towards the rear of the molten pool accelerates.

Key words: wire arc additive manufacturing, numerical simulation, multi physics field coupling, heat transfer and fluid flow

中图分类号:

TG442

赵文勇, 魏艳红, 胥国祥, 胡庆贤, 王耀伟. 基于一体化模型的铝合金MIG增材单道形貌、传热及流动行为研究[J]. 机械工程学报, 2025, 61(22): 97-108.

ZHAO Wenyong, WEI Yanhong, XU Guoxiang, HU Qingxian, WANG Yaowei. Research on the Morphology, Heat Transfer, and Metal Flow Behavior of MIG-based Wire Arc Additively Manufactured Single-pass Aluminum Alloy via Integrated Model[J]. Journal of Mechanical Engineering, 2025, 61(22): 97-108.

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基于一体化模型的铝合金MIG增材单道形貌、传热及流动行为研究

Research on the Morphology, Heat Transfer, and Metal Flow Behavior of MIG-based Wire Arc Additively Manufactured Single-pass Aluminum Alloy via Integrated Model

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