Effect of thermo-mechanical treatment on microstructure and mechanical properties of wire-arc additively manufactured Al-Cu alloy

Wire-arc additive manufacture(WAAM)has great potential for manufacturing of Al-Cu components.However,inferior mechanical properties of WAAM deposited material restrict its industrial application.Inter-layer cold rolling and thermo-mechanical heat treatment(T8)with pre-stretching deformation between solution and aging treatment were adopted in this study.Their effects on hardness,mechanical properties and microstructure were analyzed and compared to the conventional heat treatment(T6).The results show that cold rolling increases the hardness and strengths,which further increase with T8 treatment.The ultimate tensile strength(UTS)of 513 MPa and yield stress(YS)of 413 MPa can be obtained in the inter-layer cold-rolled sample with T8 treatment,which is much higher than that in the as-deposited samples.The cold-rolled samples show higher elongation than that of as-deposited ones due to significant elimination of porosity in cold rolling;while both the T6 and T8 treatments decrease the elongation.The cold rolling and pre-stretching deformation both contribute to the formation of dense and dispersive precipitatedθ′phases,which inhibits the dislocation movement and enhances the strengths;as a result,T8 treatment shows better strengthening effect than the T6 treatment.The strengthening mechanism was analyzed and it was mainly related to work hardening and precipitation strengthening.

Revealing precipitation behavior and mechanical response of wire-arc directed energy deposited Mg-Gd-Y-Zr alloy by tailoring aging procedures

Mg-Gd-Y-Zr alloy,as a typical magnesium rare-earth(Mg-RE)alloy,is gaining popularity in the advanced equipment manufacturing fields owing to its noticeable age-hardening properties and high specific strength.However,it is extremely challenging to prepare wrought components with large dimensions and complex shapes because of the poor room-temperature processability of Mg-Gd-Y-Zr alloy.Herein,we report a wire-arc directed energy deposited(DED)Mg-10.45Gd-2.27Y-0.52Zr(wt.%,GW102K)alloy with high RE content presenting a prominent combination of strength and ductility,realized by tailored nanoprecipitates through an optimized heat treatment procedure.Specifically,the solution-treated sample exhibits excellent ductility with an elongation(EL)of(14.6±0.1)%,while the aging-treated sample at 200°C for 58 h achieves an ultra-high ultimate tensile strength(UTS)of(371±1.5)MPa.Besides,the aging-treated sample at 250°C for 16 h attains a good strength-ductility synergy with a UTS of(316±2.1)MPa and a EL of(8.5±0.1)%.Particularly,the evolution mechanisms of precipitation response induced by various aging parameters and deformation behavior caused by nanoprecipitates type were also systematically revealed.The excellent ductility resulted from coordinating localized strains facilitated by active slip activity.And the ultra-high strength should be ascribed to the dense nano-β'hampering dislocation motion.Additionally,the shearable nano-β1 contributed to the good strength-ductility synergy.This work thus offers insightful understanding into the nanoprecipitates manipulation and performance tailoring for the wire-arc DED preparation of large-sized Mg-Gd-Y-Zr components with complex geometries.

Effect of wire-arc directed energy deposition on the microstructural formation and age-hardening response of the Mg-9Al-1Zn(AZ91)alloy

In recent years,wire-arc directed energy deposition(wa DED),which is also commonly known as wire-arc additive manufacturing(WAAM),has emerged as a promising new fabrication technique for magnesium alloys.The major reason for this is the possibility of producing parts with a complex geometry as well as a fine-grained microstructure.While the process has been shown to be applicable for Mg-Al-Zn alloys,there is still a lack of knowledge in terms of the influence of the WAAM process on the age-hardening response.Consequently,this study deals with the aging response of a WAAM AZ91 alloy.In order to fully understand the mechanisms during aging,first,the as-built condition was analyzed by means of high-energy X-ray diffraction(HEXRD)and scanning electron microscopy.These investigations revealed a finegrained,equiaxed microstructure with adjacent areas of alternating Al content.Subsequently,the difference between single-and double-step aging as well as conventional and direct aging was studied on the as-built WAAM AZ91 alloy for the first time.The aging response during the various heat treatments was monitored via in situ HEXRD experiments.Corroborating electron microscopy and hardness studies were conducted.The results showed that the application of a double-step aging heat treatment at 325℃with pre-aging at 250℃slightly improves the mechanical properties when compared to the single-step heat treatment at 325℃.However,the hardness decreases considerably after the pre-aging step.Thus,aging at lower temperatures is preferable within the investigated temperature range of 250-325℃.Moreover,no significant difference between the conventionally aged and directly aged samples was found.Lastly,the specimens showed enhanced precipitation kinetics during aging as compared to cast samples.This could be attributed to a higher amount of nucleation sites and the particular temperature profile of the solution heat treatment.

Enhanced Strength-Ductility Synergy in Submerged Friction Stir Processing ER2319 Alloy Manufactured by Wire-Arc Additive Manufacturing via Creating Ultrafine Microstructure

Submerged friction stir processing(SFSP)with flowing water was employed to alleviate the porosities and coarse-grained structure introduced by wire-arc manufacturing.As a result,uniform and ultrafine grained(UFG)structure with average grain size of 0.83μm was achieved with the help of sharply reduced heat input and holding time at elevated temperature.The optimized UFG structure enabled a superior combination of strength and ductility with high ultimate tensile strength and elongation of 273.17 MPa and 15.39%.Specifically,grain refinement strengthening and decentralized θ(Al_(2)Cu)phase in the sample subjected to SFSP made great contributions to the enhanced strength.In addition,the decrease in residual stresses and removal of pores substantially enhance the ductility.High rates of cooling and low temperature cycling,which are facilitated by the water-cooling environment throughout the machining process,are vital in obtaining superior microstructures.This work provides a new method for developing a uniform and UFG structure with excellent mechanical properties.

Improvement of microstructure and fatigue performance of wire-arc additive manufacture d 4043 aluminum alloy assiste d by interlayer friction stir processing

To expand the application of wire-arc additive manufacturing(WAAM)in aluminum alloy forming com-ponents,it is vitally important to reduce the porosity,refine microstructure,and thereby improve the mechanical properties of the components.In this study,the interlayer friction stir processing(FSP)tech-nique was employed to assist the WAAM of 4043 Al-Si alloy,and the related effects on the microstruc-ture evolutions and mechanical properties of the fabricated builds were systematacially investigated.As compared to the conventional WAAM processing of Al-Si alloy,it was found that the introduction of in-terlayer FSP can effectively eliminate the pores,and both theα-Al dendrites and Si-rich eutectic network were severely broken up,leading to a remarkable enhancement in ductility and fatigue performance.The average yield strength(YS)and ultimate tensile strength(UTS)of the Al-based components produced by the combination of WAAM and interlayer FSP methods were 88 and 148 MPa,respectively.Meanwhile,the elongation(EL)of 37.5%and 28.8%can be achieved in the horizontal and vertical directions,respec-tively.Such anisotropy of EL was attributed to the inhomogeneous microstructure in the stir zone(SZ).Notably,the stress concentration can be effectively reduced by the elimination of porosity and Si-rich eu-tectic network fragmentation by the interlayer FSP,and thus the fatigue behavior was improved with the fatigue strength and elongation increased by∼28%and∼108.7%,respectively.It is anticipated that this study will provide a powerful strategy and theoretical guidance for the WAAM fabrication of Al-based alloy components with high ductility and fatigue performance.

Microstructure and mechanical properties of 600 MPa grade ultra-high strength aluminum alloy fabricated by wire-arc additive manufacturing

The utilization of wire-arc additive manufacturing(WAAM)technology for the preparation of Al-Zn-Mg-Cu aluminum alloy has made some progress in recent years.However,the challenge still remains to achieve ultra-high strength(600 MPa)in WAAM.In this study,the crack-free Al-Zn-Mg-Cu-Sc thin-wall component with ultra-high strength was successfully fabricated by the cold metal transfer(CMT)pro-cess using a self-prepared 7B55-Sc filler wire.The microstructures of both as-deposited and T6 heat-treated samples were all composed of fine equiaxed grains with an average size of about 6.0μm.The primary Al_(3)(Sc,Zr)particles acted as heterogeneous nuclei to promote the formation of equiaxed grains and refine the microstructures during the solidification process.A large amount of continuous eutectic structures rich in Al,Zn,Mg,and Cu elements formed along the grain boundaries under the as-deposited condition,and the precipitated second phases within the grains mainly included the equilibriumηphase,metastableηphase and large-sized T phase.After T6 heat treatment,the majority of the second phases originally distributed within grains and along grain boundaries were dissolved into the Al matrix,and a large amount of fine GP zones,ηphase and secondary Al_(3)(Sc,Zr)particles were precipitated within the grains during the aging process.The tensile strength reached a recorded level of 618 MPa in the hori-zontal direction after T6 heat treatment,which was considered a breakthrough for the manufacturing of 600 MPa grade aluminum alloy by WAAM.

基于等腰梯形截面的多层单道有限元几何建模及合理性分析

提出了一种基于等腰梯形截面的WAAM多层单道有限元热力耦合仿真建模方法。首先,基于单层单道的等腰梯形函数模型,建立多层单道梯形函数模型。然后,通过对比多层单道的梯形函数模型和抛物线函数模型的几何偏差和散热性能指标,验证了多层单道梯形函数模型的合理性,并对多层单道沉积过程进行热力耦合仿真分析和对应的试验验证。仿真与试验结果表明,多层单道梯形函数模型的模拟结果与抛物线函数模型及试验结果均吻合较好,计算效率也得到一定的提高。

电弧熔丝增材制造控形技术研究现状与展望

金属增材制造是制造强国战略下推动我国高端装备制造业转型升级的重点发展方向。电弧增材制造以其高沉积效率、低成本、可进行复杂结构直接成形等优势受到了广泛的关注。但增材过程中涉及的物理过程复杂,成形质量与精度面临很大挑战。针对电弧增材制造技术短流程、长周期的制造特征,讨论如何从热源上降低成形偏差、从过程上降低制造误差、从结果上改善成形精度,介绍了一系列创新的热源调制、过程控制与结果优化的方法策略,总结了现有技术存在的问题与面临的挑战,为如何进一步提升电弧增材过程的成形控制效果提出了几点思考。

机械振动对电弧增材制造2319铝合金微观组织与机械性能的影响

为了解决电弧增材制造试样晶粒粗大、机械性能较差等问题,在电弧增材制造2319铝合金过程中施加机械振动,分析了机械振动频率和幅度对试样微观组织和机械性能的影响。结果显示:机械振动使熔池流动性提高,熔池更加铺展,层宽增加,层高降低;振动破碎了生长过程中的枝晶,使INZ晶粒尺寸减小14.49μm,ITZ晶粒尺寸减小4.68μm;枝晶间隙处的溶质元素含量降低,晶界析出相变得断续且细小,PLC效应间隔增加,材料延伸率显著提高;机械振动频率和机械振动幅度改变时纵向和横向延伸率分别提升了38.2%,15.7%和29.3%,52.5%,而强度变化并不显著。采用机械振动辅助电弧增材制造能够在不影响强度的前提下显著提高试样的塑性,可为机械振动在增材制造领域的广泛应用提供技术参考。

低合金高强钢焊丝熔滴过渡形态及飞溅分析研究

利用高速摄像系统对自主研发低合金高强钢焊丝焊接过程的熔滴进行拍摄,分析整个焊接过程中的熔滴过渡模式与飞溅产生机理,研究合金元素与焊接热输入对焊丝的熔滴过渡形态产生的影响。试验结果表明,焊接过程中出现了滴状过渡、短路过渡、射滴过渡3种熔滴过渡模式与电弧力引起的飞溅、爆炸飞溅、熔池偏飞、颗粒偏飞4种飞溅形式。合金元素含量改变了熔滴的物理化学性质,焊接热输入改变熔滴的受力与熔滴熔池形态,从而改变了焊接过程中熔滴过渡与飞溅形式。通过综合比较分析,发现#3焊丝的焊接过程电弧最稳定,飞溅最小。

镁合金电弧增材制造研究现状及展望

电弧增材制造由于其高沉积速率、高材料利用率、低成本以及具有制造大尺寸构件的能力而得到研究人员的广泛关注,有望广泛应用于镁合金的快速成形。本文概述了电弧增材制造用镁合金丝材的种类及其对丝材的要求,总结了现今适合于镁合金电弧增材制造用丝材的制备方法,重点论述了镁合金电弧增材制造工艺的制备技术、基本原理、微观组织及力学性能,讨论了不同电弧增材制造工艺制备不同镁合金的影响因素,分析了镁合金电弧增材制造目前可用丝材种类少以及增材制造构件形性尚不可控等问题,并且在优化电弧增材制造镁合金构件性能和推进应用方面进行了展望。

基于工程应用的CW-GMAW熔滴过渡形态表征

综述了涉及工程应用的冷丝熔化极气体保护焊(Cold wire gas metal arc welding,CW-GMAW)熔滴过渡形态特征。结果表明,在大电流、强规范、富氩混合气体保护下,CW-GMAW工艺的熔滴过渡形态呈喷射过渡;当电流较小、电弧电压较低时,可能为滴状过渡,甚至在弧压很低时,呈现短路过渡形态。该工艺电弧发生偏向冷丝的位移,弧长变短甚至发生短路,与冷丝送进速率比增高及冷丝在电弧中产生大量金属蒸气时弧柱电阻下降有关。在具有富氩混合保护气体的相同工艺参数下,CWGMAW转变电流比GMAW降低了4%~7%。焊接工艺参数对CW-GMAW和GMAW工艺熔滴过渡形态的影响规律大致相近,但前者因涉及冷丝送进速率比和电极焊丝送进速度,以及它们的匹配等,使焊接电流的影响更为复杂。

高强铝合金电弧增材制造的研究进展

高强铝合金因具有高强度、低密度、优异的延展性和抗腐蚀性,成为了航空航天和汽车应用零件最常用的金属材料之一。电弧增材制造技术具有快速原位成形制造复杂结构零部件的能力,非常适用于中型或大型高强铝合金铝部件的制造。本文综合分析了高强铝合金电弧增材制造工艺和设备研发现状、高强铝合金电弧增材的固有属性和缺陷以及主要的性能优化手段,讨论了组织和性能的固有特征和复合增材制造技术对组织和性能的影响。针对电弧增材制造高强铝合金不可忽略的本质冶金缺陷、特征性能需求和多种优化工艺的优劣等问题,提出了电弧增材制造高强铝合金综合评价体系、成分设计和丝材开发、专用热处理制度和复合增材制造技术的协同性等发展方向,以期为电弧增材制造高强铝合金的性能提升和应用推广提供重要参考。

辅丝对摇动电弧窄间隙GMA焊接温度场的影响

【目的】旨在建立主辅丝同步的摇动电弧窄间隙GMA焊温度场模型。【方法】从宏观传热学出发,综合考虑横断面几何形状特征、主丝和辅丝的运动及焊缝表面形状对电弧热流分布特征的影响,并利用ANSYS软件对不加辅丝和主辅丝同步摇动两种情况下的电弧瞬态温度场及热循环曲线进行了模拟计算。【结果】焊缝横断面的计算结果、测温特征点热循环曲线的计算结果,与试验结果接近。【结论】证明模型可以真实反映添加辅丝的摇动电弧的移动轨迹及分布特征,具有较高的准确性。不加辅丝时,焊缝横断面底部有明显“双峰”特征,主辅丝同步摇动时,“双峰”特征明显减弱。主辅丝同步摇动情况下的热影响区宽度略有增加。

旋转电弧焊接技术研究进展

熔焊焊接时会不可避免地出现侧壁不熔、咬边、晶粒粗大等问题,导致接头性能较低。为更好地解决焊接中存在的问题,提出旋转电弧焊接技术。相对于普通焊接,旋转电弧中的旋转电弧耦合力在焊接时对熔池的搅拌破碎效应能加速焊缝中的传质传热,并细化晶粒减小焊缝残余应力,能解决焊接中常见问题,获得优质焊缝并提高焊接接头的使用寿命。主要综述了基于外加磁场、非对称钨极旋转电弧、缆式焊丝熔化极旋转电弧的研究现状,指出目前旋转电弧焊接技术还存在的问题,并对相关技术的应用前景进行展望。

微量TiC粉末合金化改善电弧增材制造Ti-6Al-4V合金的组织和性能

原位合金化是调控增材制造钛合金微观组织和力学性能的有效方法,文中研究了添加微量TiC粉末对电弧增材制造Ti-6Al-4V合金微观组织和力学性能的影响.结果表明,添加微量TiC粉末后,Ti-6Al-4V合金中的柱状β晶粒尺寸减小,α-Ti相细化,微观组织为精细的网篮组织,抗拉强度和断后伸长率达到了1029 MPa和14.8%,分别提高了12.8%和26.5%,实现了电弧增材制造Ti-6Al-4V合金强度和塑性的协同改善.同时,沉积合金的显微硬度提高至362.9HV,相比Ti-6Al-4V合金提高了11.4%.通过电子背散射衍射(electron backscatter diffraction,EBSD)分析得出,TiC粉末的添加降低了沉积合金的织构强度,增加α-Ti相的取向.添加微量TiC粉末后,Ti-6Al-4V合金力学性能的提高主要归因于细晶强化和固溶强化效应,其中细晶强化是主要的强化机制.对比分析两种沉积合金的拉伸试样断口得出,Ti-6Al-4V合金的断口形貌呈现出塑性-脆性混合断裂,添加质量分数0.5%TiC粉末后,断口形貌呈现出塑性断裂.证实了TiC粉末作为电弧增材制造Ti-6Al-4V合金晶粒细化剂的潜力.

添加钽对电弧熔丝增材制备镍钛形状记忆合金组织性能的影响

NiTiTa三元形状记忆合金(SMAs)是潜在的生物医用材料,且电弧增材制造(WAAM)技术已经广泛应用于NiTi合金的研究中,研究Ta添加对WAAM的NiTi合金组织性能的影响具有重要意义.利用WAAM技术分别制造了5层NiTi合金和NiTiTa合金薄壁构件,系统研究了Ta添加对NiTi合金的微观组织、相变行为、力学性能以及抗腐蚀能力的影响.结果表明,与NiTi合金相比,NiTiTa合金的晶粒显著细化,析出相由NiTi合金中的Ni3Ti转变为Ni(Ti,Ta)_(2).此外,其相变温度显著提高,导致了室温下的组织由完全奥氏体相(B2)转变为奥氏体(B2)和马氏体(B19’)的混合相.拉伸试验结果表明,NiTiTa合金试样相较于NiTi合金试样的抗拉强度提升了9.5%,但延伸率下降了6.8%.极化曲线结果表明,NiTiTa合金具有更高的自腐蚀电位和更小的腐蚀电流密度,抗腐蚀能力显著提升.本研究为促进WAAM制备的NiTiTa合金及其在生物医疗领域的应用奠定了研究基础.

2219铝合金CMT电弧增材熔滴过渡行为

在冷金属过渡(cold metal transfer,CMT)电弧增材制造过程中,熔池的流动行为极易受到电弧和熔滴的影响,从而严重影响堆积层的稳定性和成形件质量.该文利用高速摄影结果及电信号参数波形图,引入热输入量计算公式,从特征电信号、熔滴过渡特征量、热输入量等方面定量分析了CMT+P模式下送丝速度及脉冲修正系数对熔滴过渡过程及单道成形形貌的影响,同时分析了脉冲变极性冷金属过渡(Advanced CMT,CMT+PA)模式下送丝速度及控制面板上的EP/EN修正系数η对熔滴过渡过程及单道成形形貌的影响,为后续工艺优化提供参考和指导.

沉积策略对电弧增材制造5356铝合金显微组织、缺陷和力学性能的影响

基于电弧增材制造技术(WAAM)研究往复扫描(RS)、振荡扫描(OS)和垂直扫描(VS)3种沉积策略对5356铝合金(AA5356)构件的影响,探讨5356铝合金构件的显微组织、缺陷和力学性能。结果表明:相比于RS和OS策略,VS策略使得构件的热量分布均匀。VS策略的显微组织主要由等轴晶组成,使得显微硬度最高值达到HV 77.25。VS策略使得构件的气孔率和微孔尺寸分别下降了45.52%和19.81%,从而改善了拉伸性能。因此,VS策略为获得显微组织均匀、力学性能优异的AA5356构件提供了一种新的解决方案。

环境湿度对浸金属碳滑板磨损及温升的影响

为探究环境湿度对弓网摩擦副载流滑动过程中电弧放电能量、浸金属碳滑板温升及滑板磨损量的影响,采用环-块式高速载流摩擦磨损试验台,对比不同湿度条件下,电弧能量、滑板温升及滑板磨损量随滑动速度、电流强度、法向力的变化情况。试验结果表明:不同环境湿度下,滑动速度和电流强度的增大均会导致电弧能量及滑板温升急剧增大;电弧热是导致温升的主要热源;增大法向力对于抑制电弧放电、降低滑板温升均有显著效果,而对于滑板磨损量变化的影响,不同湿度情况则截然相反;高湿度环境下接触副附着的水膜改善了接触状况和散热情况,电弧能量及滑板温升都小于低湿度环境;低湿度环境下滑板表面受到更严重的机械摩擦,其表面状态相比高湿度更差;在平均湿度较高的夏季适当增加升弓压力,在平均湿度较低的冬季适当降低列车行驶速度可以减少浸金属碳滑板磨损。