钛合金栅格薄壁结构电弧熔丝增材制造路径规划与应力控制

Deposition path planning and stress control for gridding thin-walled titanium alloy parts fabricated by wire-arc additive manufacturing

摘要

电弧熔丝增材制造（wire-arc additive manufacturing，WAAM）以金属丝材为填充材料、电弧为热源，在大型复杂构件制造中具有显著优势，但存在制备周期长，路径规划复杂及残余应力显著等问题。针对电弧熔丝增材制造制备复杂结构件时，不合理制备路径导致的残余应力集中与应变缺陷，使用有限元仿真软件优化沉积路径，并基于优化路径制备成形质量良好的栅格构件单元体。结果表明：未优化路径冷却后，薄壁处等效残余应力为 361 MPa，节点处高达 666 MPa；而优化路径冷却后薄壁处等效残余应力将至 206 MPa，两节点处分别为 260、427 MPa。相较于未优化路径，优化路径节点残余应力最大降幅 61%，薄壁应力降幅 43%，且节点与薄壁的应力差异显著降小，残余应力诱发的形变与缺陷明显降低。采用优化路径制备的栅格构件单元体熔道结合紧密、成形质量良好，无明显残余应力变形，验证了此优化路径在电弧熔丝增材制造栅格构件残余应力控制中的可行性。

Abstract

Wire-arc additive manufacturing (WAMM) is an emerging manufacturing technology that employs metal wire as the raw material and arc as the heat source. It offers advantages in fabricating large and complex parts. Nevertheless, it still faces challenges, including prolonged fabrication cycles, intricate path planning, and substantial residual stress. In this study, we explore the optimization of the manufacturing path for wire-arc additive manufacturing when fabricating complex structural components, aiming to mitigate the significant residual stress and strain induced by suboptimal manufacturing paths. Finite element software is utilized to optimize the manufacturing path, and a unit body of a grid component with excellent forming quality has been successfully produced using the optimized path. Through finite element analysis, it can be revealed that for the unoptimized path, the equivalent residual stress at the thin-wall after cooling reaches 361 MPa, while that at the nodes after cooling is 666 MPa. In contrast, for the optimized path, the equivalent residual stress at the thin-wall after cooling is 206 MPa, and the equivalent residual stresses at two nodes after cooling are 260 MPa and 427 MPa, respectively. Compared to the unoptimized path, the optimized path leads to a 61% reduction in residual stress at the nodes and a 43% decrease in stress at the thin-wall. Moreover, the difference in residual stress between the nodes and the thin-wall is smaller than that of the unoptimized path, resulting in less deformation and fewer defects caused by residual stress. The grid component unit body fabricated using the optimized path exhibits well-combined melt tracks and superior forming quality, with no discernible residual stress deformation. This effectively validates the feasibility of the optimized path in controlling residual stress during the wire-arc additive manufacturing of grid components.

关键词

电弧熔丝增材制造 / 钛合金构件 / 有限元分析 / 路径规划

Key words

wire arc additive manufacturing / titanium alloy part / finite element analysis / path planning

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基金资助

国家重点研发计划科技型中小企业项目(2024YFB4610300)