Additive manufacturing(AM)of Mg alloys has become a promising strategy for producing complex structures,but the corrosion performance of AM Mg components remains unexploited.In this study,wire and arc additive manufac...Additive manufacturing(AM)of Mg alloys has become a promising strategy for producing complex structures,but the corrosion performance of AM Mg components remains unexploited.In this study,wire and arc additive manufacturing(WAAM)was employed to produce single AZ31 layer.The results revealed that the WAAM AZ31 was characterized by significant grain refinement with non-textured crystallographic orientation,similar phase composition and stabilized corrosion performance comparing to the cast AZ31.These varied corrosion behaviors were principally ascribed to the size of grain,where cast AZ31 and WAAM AZ31 were featured by micro galvanic corrosion and intergranular corrosion,respectively.展开更多
Finite element (FE) coupled thermal-mechanical analysis is widely used to predict the deformation and residualstress of wire arc additive manufacturing (WAAM) parts. In this study, an innovative single-layermulti-bead...Finite element (FE) coupled thermal-mechanical analysis is widely used to predict the deformation and residualstress of wire arc additive manufacturing (WAAM) parts. In this study, an innovative single-layermulti-bead profilegeometric modeling method through the isosceles trapezoid function is proposed to build the FE model of theWAAMprocess. Firstly, a straight-line model for overlapping beads based on the parabola function was establishedto calculate the optimal center distance. Then, the isosceles trapezoid-based profile was employed to replace theparabola profiles of the parabola-based overlapping model to establish an innovative isosceles trapezoid-basedmulti-bead overlapping geometric model. The rationality of the isosceles trapezoid-based overlapping model wasconfirmed by comparing the geometric deviation and the heat dissipation performance index of the two overlappingmodels. In addition, the FE-coupled thermal-mechanical analysis, as well as a comparative experiment of thesingle-layer eight-bead deposition process show that the simulation results of the above two models agree with theexperimental results. At the same time, the proposed isosceles trapezoid-based overlappingmodels are all straightlineprofiles, which can be divided into high-quality FE elements. It can improve the modeling efficiency andshorten the simulation calculation time. The innovative modeling method proposed in this study can provide anefficient and high-precision geometricmodelingmethod forWAAMpart FE coupled thermal-mechanical analysis.展开更多
Wire arc additive manufacturing(WAAM)is one of the most promising approaches to manufacturing large and complex metal components owing to its low cost and high efficiency.However,pores and coarse columnar grains cause...Wire arc additive manufacturing(WAAM)is one of the most promising approaches to manufacturing large and complex metal components owing to its low cost and high efficiency.However,pores and coarse columnar grains caused by thermal accumulation in WAAM significantly decrease the strength and increase the anisotropy,preventing the achievement of both high strength and isotropy.In this study,the strength and anisotropy of AlMg-Sc-Zr alloys were improved by regulating heat input.The results indicated that as the heat input increased from 60 to 99 J/mm,all the components had lower porosity(lower than 0.04%),the size of the Al_(3)(Sc_(1-x),Zr_(x))phases decreased,and the number density increased.The average grain size gradually decreased,and the grain morphologies transformed from coarse equiaxed grain(CEG)+fine equiaxed grain(FEG)to FEG owing to the increase in Al_(3)(Sc_(1-x),Zr_(x))phases with increasing heat input.After heat treatment at 325℃for 6 h,high-density dispersed Al_(3)Sc phases(<10 nm)precipitated.The alloy possessed the highest strength at 79 J/mm,ultimate tensile strength(UTS)of approximately 423±3 MPa,and in-plane anisotropy of approximately 4.3%.At a heat input of 99 J/mm,the in-plane anisotropy decreased to 1.2%and UTS reached 414±5 MPa.The reduction in the CEG prolonged the crack propagation path,which improved the UTS in the vertical direction and reduced the anisotropy.Theoretical calculations indicated that the main strengthening mechanisms were solid solution and precipitation strengthening.This study lays the theoretical foundations for WAAM-processed high-strength and isotropic Al alloy components.展开更多
基金the financial support by National Key Research and Development Project(Grand No.2020YFC1107202)Guangdong Basic and Applied Basic Research Foundation(Grand No.2020A1515110754)+3 种基金MOE Key Lab of Disaster Forest and Control in Engineering,Jinan University(Grand No.20200904008)Educational Commission of Guangdong Province(Grand No.2020KTSCX012)the Fundamental Research Funds for Central Universities(Grand No.21620342)the support from National Natural Science Foundation of China,NSFC(Grand No.51775556)。
文摘Additive manufacturing(AM)of Mg alloys has become a promising strategy for producing complex structures,but the corrosion performance of AM Mg components remains unexploited.In this study,wire and arc additive manufacturing(WAAM)was employed to produce single AZ31 layer.The results revealed that the WAAM AZ31 was characterized by significant grain refinement with non-textured crystallographic orientation,similar phase composition and stabilized corrosion performance comparing to the cast AZ31.These varied corrosion behaviors were principally ascribed to the size of grain,where cast AZ31 and WAAM AZ31 were featured by micro galvanic corrosion and intergranular corrosion,respectively.
基金the National Natural Science Foundation of China(Grant No.51705287)the Scientific Research Foundation of Hubei Provincial Education Department(Grant No.D20211203).
文摘Finite element (FE) coupled thermal-mechanical analysis is widely used to predict the deformation and residualstress of wire arc additive manufacturing (WAAM) parts. In this study, an innovative single-layermulti-bead profilegeometric modeling method through the isosceles trapezoid function is proposed to build the FE model of theWAAMprocess. Firstly, a straight-line model for overlapping beads based on the parabola function was establishedto calculate the optimal center distance. Then, the isosceles trapezoid-based profile was employed to replace theparabola profiles of the parabola-based overlapping model to establish an innovative isosceles trapezoid-basedmulti-bead overlapping geometric model. The rationality of the isosceles trapezoid-based overlapping model wasconfirmed by comparing the geometric deviation and the heat dissipation performance index of the two overlappingmodels. In addition, the FE-coupled thermal-mechanical analysis, as well as a comparative experiment of thesingle-layer eight-bead deposition process show that the simulation results of the above two models agree with theexperimental results. At the same time, the proposed isosceles trapezoid-based overlappingmodels are all straightlineprofiles, which can be divided into high-quality FE elements. It can improve the modeling efficiency andshorten the simulation calculation time. The innovative modeling method proposed in this study can provide anefficient and high-precision geometricmodelingmethod forWAAMpart FE coupled thermal-mechanical analysis.
基金supported by National Key Research and Development Program(Grant No.2024YFB4609700)the National Natural Science Foundation of China(Grant No.52374365)。
文摘Wire arc additive manufacturing(WAAM)is one of the most promising approaches to manufacturing large and complex metal components owing to its low cost and high efficiency.However,pores and coarse columnar grains caused by thermal accumulation in WAAM significantly decrease the strength and increase the anisotropy,preventing the achievement of both high strength and isotropy.In this study,the strength and anisotropy of AlMg-Sc-Zr alloys were improved by regulating heat input.The results indicated that as the heat input increased from 60 to 99 J/mm,all the components had lower porosity(lower than 0.04%),the size of the Al_(3)(Sc_(1-x),Zr_(x))phases decreased,and the number density increased.The average grain size gradually decreased,and the grain morphologies transformed from coarse equiaxed grain(CEG)+fine equiaxed grain(FEG)to FEG owing to the increase in Al_(3)(Sc_(1-x),Zr_(x))phases with increasing heat input.After heat treatment at 325℃for 6 h,high-density dispersed Al_(3)Sc phases(<10 nm)precipitated.The alloy possessed the highest strength at 79 J/mm,ultimate tensile strength(UTS)of approximately 423±3 MPa,and in-plane anisotropy of approximately 4.3%.At a heat input of 99 J/mm,the in-plane anisotropy decreased to 1.2%and UTS reached 414±5 MPa.The reduction in the CEG prolonged the crack propagation path,which improved the UTS in the vertical direction and reduced the anisotropy.Theoretical calculations indicated that the main strengthening mechanisms were solid solution and precipitation strengthening.This study lays the theoretical foundations for WAAM-processed high-strength and isotropic Al alloy components.
