Study on Wire Arc Additive Manufacturing of SiC Aluminum Alloy Composite Gradient Space Exploration Structure

doi:10.3901/JME.260136

Abstract

Abstract: The gradient space exploration structure containing SiC 2 wt.% or more has good deformation resistance and is often used to prepare hypersonic vehicle seeker. The fine core wire of aluminum alloy containing SiC with good technological properties was developed, the structure characteristics of aluminum alloy material gradient space probe were analyzed, and the double wire arc additive manufacturing technology was studied. The results show that the developed Al-Si-SiC alloy system has little influence on the stability of main wire arc in the process of double wire arc additive manufacturing, and the deposited metal has high strength and high elastic modulus. The aluminum alloy gradient space detection structure was analyzed, and the aluminum alloy gradient space detection structure with SiC gradient varying from 2 wt.%-4 wt.% was prepared by adopting the zonal forming strategy and the forming precision control method of the axial wire feeding arc additive manufacturing components. The average size deviation of the structural components was ±1.16 mm. Under a 5g acceleration and a 10 min vibration test, there was no significant deformation or cracking observed, demonstrating strong resistance to vibration-induced deformation. The research results provide theoretical basis and basic data for the preparation of high performance ceramic phase modified aerospace complex aluminum alloy components.

Key words: SiC, material gradient structure, double wire arc additive manufacturing, aluminium alloy

CLC Number:

TG47

ZHENG Bo, YU Shengfu, YU Zhenyu, MENG Xiaohao. Study on Wire Arc Additive Manufacturing of SiC Aluminum Alloy Composite Gradient Space Exploration Structure[J]. Journal of Mechanical Engineering, 2026, 62(4): 107-117.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260136

http://www.cjmenet.com.cn/EN/Y2026/V62/I4/107

References

[1] LI Shuangshuang，YUE Xin，LI Qingyuan，et al. Development and applications of aluminum alloys for aerospace industry[J]. Journal of Materials Research and Technology，2023，27：944-983.
[2] 丁延卫，尤政，卢锷，等. 航天光学遥感器光机结构尺寸稳定性变化对成像质量的影响[J]. 光学与光电技术，2004，2(3)：1-4. DING Yanwei，YOU Zheng，LU E，et al. Influence of dimensional stability change of opto-mechanical structure of aerospace optical remote sensor on imaging quality[J]. Optics & Optoelectronic Technology，2004，2(3)：1-4.
[3] 马晓平，赵良玉. 红外导引头关键技术国内外研究现状综述[J]. 航空兵器，2018，25(3)：3-10. MA Xiaoping，ZHAO Liangyu. An overview of infrared seeker key technologies at home and abroad[J]. Aero Weaponry，2018，25(3)：3-10.
[4] 马宗义，肖伯律，张峻凡，等. 航天装备牵引下的铝基复合材料研究进展与展望[J]. 金属学报，2023，59(4)：457-466. MA Zongyi，XIAO Bolü，ZHANG Junfan，et al. Overview of research and development for aluminum matrix composites driven by aerospace equipment demand[J]. Acta Metallurgica Sinica，2023，59(4)：457-466.
[5] JAFARI D，VANEKER T H J，GIBSON I. Wire and arc additive manufacturing：Opportunities and challenges to control the quality and accuracy of manufactured parts[J]. Materials & Design，2021，202：109471.
[6] HAMRANI A，BOUARAB F Z，AGARWAL A，et al. Advancements and applications of multiple wire processes in additive manufacturing：A comprehensive systematic review[J]. Virtual and Physical Prototyping，2023，18(1)：e2273303.
[7] 齐膑，余圣甫，王杰，等. 多向钢节点电弧增材制造药芯丝材开发及应用[J]. 现代制造工程，2021(8)：26-32，39. QI Bin，YU Shengfu，WANG Jie，et al. Development and application of multi-directional steel node arc and wire additive manufacturing flux cored wire[J]. Modern Manufacturing Engineering，2021(8)：26-32，39.
[8] 代轶励，余圣甫，史玉升，等. 电弧熔丝增材制造460 MPa级建筑钢十向节点用药芯丝材的开发及应用[J]. 机械工程材料，2019，43(10)：24-29，52. DAI Yili，YU Shengfu，SHI Yusheng，et al. Development and application of flux cored wire for wire-arc additive manufacturing of 460 MPa grade building ten-directional steel point[J]. Materials for Mechanical Engineering，2019，43(10)：24-29，52.
[9] TREUTLER K，LORENZ S，HAMJE J，et al. Wire and arc additive manufacturing of a CoCrFeMoNiV complex concentrated alloy using metal-cored wire：Process，properties，and wear resistance[J]. Applied Sciences，2022，12(13)：6308.
[10] 闫欢. 多丝熔化极电弧增材制造高强铝合金工艺及性能研究[D]. 石家庄：河北科技大学，2023. YAN Huan. Research on the process and properties of high-strength aluminum alloy fabricated by multi-wire melting electrode arc additive manufacturing [D]. Shijiazhuang：Hebei University of Science and Technology，2023.
[11] 罗晓宇，冯曰海，鄂炫宇，等. 双丝钨极氩弧增材制造高镁组分Al-Mg合金的组织与性能[J]. 中国有色金属学报，2022，32(4)：951-961. LUO Xiaoyu，FENG Yuehai，E Xuanyu，et al. Microstructure and mechanical properties of high Mg content Al-Mg alloys by double wires gas tungsten arc additive manufacturing process[J]. The Chinese Journal of Nonferrous Metals，2022，32(4)：951-961.
[12] SHEN Chen，PAN Zengxi，CUIURI D，et al. Fabrication of Fe-FeAl functionally graded material using the wire-arc additive manufacturing process[J]. Metallurgical and Materials Transactions B，2016，47(1)：763-772.
[13] DING Donghong，PAN Zengxi，CUIURI D，et al. Automatic multi-direction slicing algorithms for wire based additive manufacturing[J]. Robotics and Computer-Integrated Manufacturing，2016，37：139-150.
[14] HE Tianying，YU Shengfu，HUANG Anguo，et al. Path planning and forming of wire multi-arc additive collaborative manufacture for marine propeller bracket[J]. Journal of Manufacturing Processes，2021，68：1191-1201.
[15] 何天英. 高性能金属构件多电弧协同增材制造关键技术研究[D]. 武汉：华中科技大学，2022. HE Tianying. Research on key technologies of multi-arc collaborative additive manufacturing for high- performance metal components[D]. Wuhan：Huazhong University of Science and Technology，2022.
[16] FAROUKI R T，KOENIG T，TARABANIS K A，et al. Path planning with offset curves for layered fabrication processes[J]. Journal of Manufacturing Systems，1995，14(5)：355-368.
[17] 邱丰，佟昊天，沈平，等. 综述：SiC/Al界面反应与界面结构演变规律及机制[J]. 金属学报，2019，55(1)：87-100. QIU Feng，TONG Haotian，SHEN Ping，et al. Overview：SiC/Al interface reaction and interface structure evolution mechanism[J]. Acta Metallurgica Sinica，2019，55(1)：87-100.
[18] QI Zewu，CONG Baoqiang，QI Bojin，et al. Microstructure and mechanical properties of double- wire + arc additively manufactured Al-Cu-Mg alloys[J]. Journal of Materials Processing Technology，2018，255：347-353.
[19] KOLSGAARD A，BRUSETHAUG S. Fluidity of aluminium alloy AlSi₇Mg-SiC particulate composite melts[J]. Materials Science and Technology，1994，10(6)：545-551.
[20] ORTEGA A G，GALVAN L C，SALEM M，et al. Characterisation of 4043 aluminium alloy deposits obtained by wire and arc additive manufacturing using a cold metal transfer process[J]. Science and Technology of Welding and Joining，2019，24(6)：538-547.
[21] XUE Gang，KE Linda，ZHU Haihong，et al. Influence of processing parameters on selective laser melted SiCp/AlSi10Mg composites：Densification，microstructure and mechanical properties[J]. Materials Science and Engineering：A，2019，764：138155.
[22] JIANG Wenming，ZHU Junwen，LI Guangyu，et al. Enhanced mechanical properties of 6082 aluminum alloy via SiC addition combined with squeeze casting[J]. Journal of Materials Science & Technology，2021，88：119-131.
[23] GANESH V V，CHAWLA N. Effect of particle orientation anisotropy on the tensile behavior of metal matrix composites：Experiments and microstructure-based simulation[J]. Materials Science and Engineering：A， 2005，391(1-2)：342-353.
[24] LIMA W M，VELASCO F J，ABENOJAR J，et al. Numerical approach for estimating the elastic modulus in MMCs as a function of sintering temperature[J]. Journal of Materials Processing Technology，2003，143-144：698-702.
[25] WANG Xiaolong，WANG Aimin，LI Yuebo. Study on the deposition accuracy of omni-directional GTAW-based additive manufacturing[J]. Journal of Materials Processing Technology，2020，282：116649.