多维异质异构大型构件智能增材制造研究进展

Review on intelligent additive manufacturing of multidimensional heterogeneous large components

电弧增材是近年发展起来的一种高效率、低成本、高性能、低精度整体制造方法,可成形超高强钢、轻合金等多种金属构成的一体化高性能构件.电弧-激光复合、增材-形变、增材-减材等复合成形技术,可进一步提高成形精度,提升构件韧性,更好地成形异质异构构件.本文从多维异质异构概念内涵、电弧复合增材技术、电弧增材过程智能控制等方面对多维异质异构大型构件智能电弧增材技术进行了综述,重点分析了增材过程参数-熔池视觉-应力-变形等协同传感技术;利用深度学习等人工智能方法,在线调整工艺参数,控制缺陷、抑制应力、减小变形,研制的大型多维异质构件多机器人智能复合增材装备,最大可增材10 m×4 m×4 m多金属构件;分析了电弧增材构件微观组织演变、静(动)态力学性能和抗超高速冲击性能特征;最后,指出了多维异质异构增材技术的4大发展趋势.

Intelligent additive manufacturing of multidimensional heterogeneous large components is a comprehensive manufacturing technology that uses heat sources,such as arc and laser,to melt wire(powder)materials with different compositions and deposit different metals in different regions,layer by layer,for solidification and creation of desired shapes.By integrating concepts such as biomimicry,multimetal integration design,and additive manufacturing,this emerging interdisciplinary technology enables the production of high-performance materials(components)and provides a new path for realizing high-performance manufacturing of new materials(components),which has revolutionary significance.This article provides an analysis and overview of intelligent additive manufacturing from four aspects,including the conceptual connotation of the multidimensional heterogeneous materials,wire arc composite additive technology,intelligent control of the process,and properties of wire arc additively manufactured materials.Research conducted on this technology at home and abroad indicates that this technology is an efficient and high-performance holistic manufacturing method developed in recent years.Additionally,using this technology,multimetal components,such as high-strength and ultrahigh-strength steel and lightweight alloys,can be prepared,and it exhibits a single-gun efficiency of up to 1500 cm3/h and a surface accuracy of up to 0.5 mm.The maximum size for additive manufacturing is virtually unlimited,currently reaching 10 m×4 m×4 m.To further improve accuracy,efficiency,performance,and quality of additively manufactured components,researchers worldwide have developed hybrid forming technologies,such as arc-laser hybrid,additive deformation,and additive-subtractive processes,integrating the advantages of high efficiency from arcs,high precision from the subtractive process,and high toughness from the deformation process.Because of the characteristics of short processing cycles and long periods,researchers domestically and internationally have explored collaborative sensing of parameters,such as visual perception of molten pools,stress,and deformation.Furthermore,they have utilized artificial intelligence methods,such as deep learning,to regulate heat source parameters and local heating through online control measures,effectively controlling defects,suppressing stress,reducing deformation,and enhancing performance.Hence,intelligent composite forming equipment with online control capabilities has been developed on a 10-m scale.Moreover,researchers worldwide have conducted thorough studies on the microstructure and mechanical properties of additive components,analyzed the evolution of organizational properties under multiple thermal processes,and performed tests on dynamic mechanics and resistance to high-speed impact.Based on domestic and international research analyses,this article identifies major development trends exhibited by the multidimensional heterogeneous additive manufacturing technology.