Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing addit...Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing additive-induced defects,and alleviating residual stress and deformation,all of which are critical for enhancing the mechanical performance of the manufactured parts.Integrating interlayer friction stir processing(FSP)into WAAM significantly enhances the quality of deposited materials.However,numerical simulation research focusing on elucidating the associated thermomechanical coupling mechanisms remains insufficient.A comprehensive numerical model was developed to simulate the thermomechanical coupling behavior in friction stir-assisted WAAM.The influence of post-deposition FSP on the coupled thermomechanical response of the WAAM process was analyzed quantitatively.Moreover,the residual stress distribution and deformation behavior under both single-layer and multilayer deposition conditions were investigated.Thermal analysis of different deposition layers in WAAM and friction stir-assisted WAAM was conducted.Results show that subsequent layer deposition induces partial remelting of the previously solidified layer,whereas FSP does not cause such remelting.Furthermore,thermal stress and deformation analysis confirm that interlayer FSP effectively mitigates residual stresses and distortion in WAAM components,thereby improving their structural integrity and mechanical properties.展开更多
Wire arc additive manufacturing(WAAM)has emerged as a promising technique for producing large-scale metal components,favoured by high deposition rates,flexibility and low cost.Despite its potential,the complexity of W...Wire arc additive manufacturing(WAAM)has emerged as a promising technique for producing large-scale metal components,favoured by high deposition rates,flexibility and low cost.Despite its potential,the complexity of WAAM processes,which involves intricate thermal dynamics,phase transitions,and metallurgical,mechanical,and chemical interactions,presents considerable challenges in final product qualities.Simulation technologies in WAAM have proven invaluable,providing accurate predictions in key areas such as material properties,defect identification,deposit morphology,and residual stress.These predictions play a critical role in optimising manufacturing strategies for the final product.This paper provides a comprehensive review of the simulation techniques applied in WAAM,tracing developments from 2013 to 2023.Initially,it analyses the current challenges faced by simulation methods in three main areas.Subsequently,the review explores the current modelling approaches and the applications of these simulations.Following this,the paper discusses the present state of WAAM simulation,identifying specific issues inherent to WAAM simulation itself.Finally,through a thorough review of existing literature and related analysis,the paper offers future perspectives on potential advancements in WAAM simulation strategies.展开更多
Ti-6Al-4V(Ti64)alloys are widely used in the aerospace and automotive industries owing to their excellent high-temperature mechanical properties.This study investigated the creep behavior of Ti64 samples with ultra-lo...Ti-6Al-4V(Ti64)alloys are widely used in the aerospace and automotive industries owing to their excellent high-temperature mechanical properties.This study investigated the creep behavior of Ti64 samples with ultra-lowβcontent(<1%)fabricated by wire arc additive manufacturing(WAAM)under high-temperature and high-stress conditions.The creep properties of the WAAM Ti64 samples were evaluated at 600°C and 700°C with different stresses,and they were analyzed using electron backscattered diffraction(EBSD)and transmission electron microscopy(TEM).Commercially forged Ti64 samples were used as controls to compare their microstructures.As the stress increased,the degree of recrystallization intensified,leading to finer recrystallized grains.After high-temperature deformation,theβcontent in WAAM samples increased from less than 1%to over 8%.The dislocation density was high at low deformations,and the degree of recrystallization was low,suggesting superior creep resistance of the WAAM samples.The stress exponent,EBSD,and TEM analyses confirmed that dislocation movement primarily governs creep deformation in WAAM Ti64.Conversely,the forged samples exhibited easier deformation,lower dislocation density,higher recrystallization,and inferior creep resistance.This research highlights the impact ofβcontent and microstructure on the creep behavior of Ti64.The WAAM Ti64 with ultra-lowβcontent demonstrates enhanced creep resistance compared to commercially forged samples,primarily due to its unique microstructure with closely interconnectedαphases and lowerβ-phase content.展开更多
Additive manufacturing(AM)technologies,with their high degree of flexibility,enhance material utilization in the fabrication of large magnesium alloy parts,effectively meeting the demands of complex geometries.However...Additive manufacturing(AM)technologies,with their high degree of flexibility,enhance material utilization in the fabrication of large magnesium alloy parts,effectively meeting the demands of complex geometries.However,research on the corrosion resistance of magnesium alloy components produced via AM is currently limited.This study investigates the microstructural and corrosion characteristics of AZ91D magnesium alloy fabricated by wire arc additive manufacturing(WAAM)compared to its cast counterpart.A large-sized AZ91D bulk part was deposited on an AZ31 base plate using a layer-by-layer stacking approach.The results showed that the WAAM AZ91D was featured by obviously refined grains from 228.92μm of the cast one to 52.92μm on the travel direction-through thickness(TD-TT)and 50.07μm on the normal direction-through thickness(ND-TT).The rapid solidification process of WAAM inhibited the formation of β-Mg_(17)Al_(12) phase while promoting the formation of uniformly distributed network of dislocations,the dispersive precipitation of nano Al_(8)Mn_(5) phase,as well as Zn segregation.WAAM AZ91D demonstrated the occurrence of pitting corrosion and inferior corrosion resistance compared to cast AZ91D,attributed to the micro-galvanic corrosion between the α-Mg matrix and Al_(8)Mn_(5) particles and the increased number of grain boundaries.展开更多
Owing to the lack of matching commercial welding wires,the development of wire arc additive manufacturing(WAAM)for most aluminum alloys is hindered.A wire-powder synchronous arc additive manufacturing(WPAAM)was propos...Owing to the lack of matching commercial welding wires,the development of wire arc additive manufacturing(WAAM)for most aluminum alloys is hindered.A wire-powder synchronous arc additive manufacturing(WPAAM)was proposed to prepare the target Al-Si-Mg aluminum alloy.Based on the synchronous deposition of AlSi_(12) wire and pure Mg powder,the deposition width of the WPAAMed thin-wall was increased by 61% compared with that of WAAMed thin-wall using AlSi_(12) wire,and the machining allowance was reduced by 81%.The added Mg powder benefited to form refined equiaxed grains,and reduced the average grain size of the WPAAMed thin-wall to 47.1μm,showing a decrease of 23.8% relatively to that of the WAAMed thin-wall.Besides,Mg reacted with Si to form Mg_(2)Si strengthening phases.The mechanical properties tests showed that the ultimate tensile strength and elongation of the WPAAMed thin-wall increased up to 174.5 MPa and 4.1%,reaching 92% and 60% those of the WAAMed thin-wall,respectively.展开更多
Si-containing Mg alloys solidified at conventional rates often contain coarse and sharp Mg_(2)Si phases,which can result in inferior material properties.In this study,Mg-6wt.%Si(Mg-6Si)alloy was prepared by wire arc a...Si-containing Mg alloys solidified at conventional rates often contain coarse and sharp Mg_(2)Si phases,which can result in inferior material properties.In this study,Mg-6wt.%Si(Mg-6Si)alloy was prepared by wire arc additive manufacturing(WAAM),employing the gas tungsten arc welding technique with rapid cooling.The microstructures and mechanical properties of the WAAM alloy were investigated and compared with those of the as-cast samples produced using a metal mold.The results indicate that the WAAM Mg-6Si is harder and stronger than the as-cast samples.The microhardness of the WAAM Mg-6Si increases by 36.6% in comparison to that of as-cast Mg-6Si alloy.Furthermore,the average tensile strengths at room temperature and 150℃ increases by 63.4% and 21.3%,respectively.WAAM refines both the Mg_(2)Si phase and the overall grains,resulting in a homogeneous morphology and improved mechanical properties.The granular Mg_(2)Si phase,characterized by fine particles with a diffused distribution,shows a significant increase in concentration.The acicular Mg_(2)Si phase is distributed along the grain boundaries,and its concentration significantly decreases.The average grain size of the Mg_(2)Si phase is about 9.20μm,about 5 times smaller.The refinement and distribution of the granular Mg_(2)Si phase,as well as the reduction in the amount of needle-like Mg_(2)Si particles,are the key factors for improving the mechanical properties of WAAM Mg-6Si alloy.展开更多
Heterogeneous manufacturing is a topic that continues to receive attention.As an emerging manufacturing technology,additive manufacturing can provide strong technical support for heterogeneous manufacturing.In this st...Heterogeneous manufacturing is a topic that continues to receive attention.As an emerging manufacturing technology,additive manufacturing can provide strong technical support for heterogeneous manufacturing.In this study,both homogeneous and heterogeneous composite tubular bionic components were fabricated based on the cold metal transition technology,and the influence of deposition current on the microstructure and mechanical properties of the components was studied.The results show that the interface of the as-deposited heterogeneous composite component is well bonded,and there is an obvious mechanical interlocking structure.The compressive yield strength and elongation of the heterogeneous composite components are higher than those of the homogeneous components,and are positively correlated with the deposition current.Due to the fluctuation of element content,there are a large number of fine grain structures at the interface of the heterogeneous composite components,which increases the mechanical properties.展开更多
The Mg-Gd-Y-Zn-Zr(GWZ)alloy containing a long-period ordered stacking(LPSO)phase fabricated by Wire arc additive manufacturing(WAAM)shows substantial potential in the aerospace and automotive industries.In this work,M...The Mg-Gd-Y-Zn-Zr(GWZ)alloy containing a long-period ordered stacking(LPSO)phase fabricated by Wire arc additive manufacturing(WAAM)shows substantial potential in the aerospace and automotive industries.In this work,Mg-9Gd-4Y-1Zn-0.4Zr(wt%)single-layer and multilayer components with high-forming-quality were fabricated using WAAM based on cold metal transfer(WAAM-CMT).The deposition parameters were optimized,achieving better deposition morphology and surface quality.The layer-by-layer cyclic microstructure includes remelting zone(RMZ)and non-remelting zone(NRZ),which consisted of α-Mg matrix,blocky LPSO phase,and eutectic phase.The average grain size were 26.8μm in RMZ and 39.3μm in NRZ,and the volume fraction of secondary phases was around 8%,remaining consistent across different layers.The coarse-fine-grain alternating structure generated hetero deformation induced(HDI)strengthening,while at the same time caused the fracture occurring between the NRZ and RMZ due to the weak interlayer bonding.The thermally stabilized blocky LPSO phase played an effective role on inhibiting grain growth during the solid-solution treatment.The specimen achieved highest isotropic mechanical properties after optimized heat treatment with yield strength,ultimate tensile strength,and elongation higher than 220 MPa,370 MPa,and 8.0%,respectively.The GWZ alloys fabricated by WAAM with great isotropic strength-ductility-synergy are promising candidates to replace the conventionally cast counterparts.展开更多
Additive manufacturing is a very promising manufacturing method widely used in various industries.In this study,for the first time,a new type of combined cable wire(CCW)with multi-element composition has been designed...Additive manufacturing is a very promising manufacturing method widely used in various industries.In this study,for the first time,a new type of combined cable wire(CCW)with multi-element composition has been designed and developed for arc additive manufacturing(AAM)of non-equiatomic Al-Co-Cr-FeNi high-entropy alloy.CCW composed of 7 filaments and 5 elements has the advantages of high deposition efficiency,self-rotation of welding arc and energy saving capability.Thin HEA walls were fabricated under pure argon gas using cold metal transfer technology.Microstructural observations of the developed HEA reveal(i)BCC and FCC phases,(ii)Good bonding between layers and(iii)defect-free microstructure.The developed alloy exhibits high compression strength(~2.8 GPa)coupled with high plastic strain(~42%)values(possess both strength and ductility).It has been identified that by varying the heat input via torch travel speed,the microstructure and mechanical properties of the HEA can be controlled.From this feasibility study,it has been proved that the innovative CCW method can be used to manufacture HEAs with CCW-AAM.Further,the study highlights the advantage of the rapid cooling involved in the CCW-AAM process which gives rise to superior mechanical properties.展开更多
A graded structural material(GSM)with a material transition from TA15 to TC11 was fabricated by wire arc additive manufacturing(WAAM)method.The grain morphology,chemical composition,microstructure and mechanical prope...A graded structural material(GSM)with a material transition from TA15 to TC11 was fabricated by wire arc additive manufacturing(WAAM)method.The grain morphology,chemical composition,microstructure and mechanical properties of the as-deposited GSM were all characterized to investigate their variations along the deposition direction.The results indicate that from TA15 to TC11,the grain size decreases and a transition from columnar grains to equiaxed grains occurs.The content of alloy element alters greatly within a short distance,and the width of the mutation zone is 800μm.Both TA15 and TC11 regions exhibit basketweave microstructure withα-phase andβ-phase.However,during the transition from TA15 to TC11,theα-lath becomes fine,which leads to an increase in microhardness.The tensile test shows that the bonding strength at the interface is higher than the longitudinal strength of TA15,and the lateral elongation at the interface is higher than that of TA15 and TC11.展开更多
To maximize the benefits of wire arc additive manufacturing(WAAM)processes,the effect of post-deposition heat treatment on the microstructure and mechanical properties of WAAM AZ80M magnesium(Mg)alloy was investigated...To maximize the benefits of wire arc additive manufacturing(WAAM)processes,the effect of post-deposition heat treatment on the microstructure and mechanical properties of WAAM AZ80M magnesium(Mg)alloy was investigated.Three different heat treatment procedures(T4,T5 and T6)were performed.According to the results,after T4 heat treatment,the microsegregation of alloying elements was improved with the eutectic structure dissolved.Samples after T5 heat treatment inherited the net-like distribution of secondary phases similar to the as-deposited sample,where the eutectic structure covering the interdendritic regions and theβ-phase precipitated around the eutectic structure.After T6 heat treatment,the tinyβ-phases re-precipitated from the matrix and distributed in inner and outer of the grains.The hardness distribution of the samples went through T4 and T6 heat treatment was more uniform in comparison to that of T5 heat treated samples.The tensile test showed that the T6 heat treatment improved the strength and ductility,and the anisotropy between horizontal and vertical can be eliminated.Moreover,T4 treated samples exhibited highest ductility.展开更多
Aluminum alloy is the most widely used light alloy at present.By combining different types of aluminum alloys,their functional properties can be expanded.In the present research,two components composed of 2319(Al-6.5C...Aluminum alloy is the most widely used light alloy at present.By combining different types of aluminum alloys,their functional properties can be expanded.In the present research,two components composed of 2319(Al-6.5Cu)and 5B06(Al-6.4Mg)dissimilar alloys were fabricated by wire and arc additive manufacturing(WAAM).The deposited component with the bottom half of 2319 and the top half of 5B06 exhibits better mechanical properties than its counterpart deposited vice versa.Its ultimate tensile strength,yield strength,and elongation are 258.5 MPa,139.3 MPa,and 5.6%,respectively,which are only slightly inferior to the mechanical properties of 2319 base metal.The results show that for both components,fracture occurred at a layer thickness above the interface layer during the tensile test,regardless of the deposition order.It appears that the thermal stress due to the long dwell time and the remelting of the S-AlCu Mg phase are the main factors promoting crack initiation.Depending on the deposition order,cracks propagate either along the aggregated pores or stripθ-AlCu phase distributed along the grain boundary.By analyzing the heat input and selecting the appropriate depositing order,the strength of WAAM dissimilar aluminum alloys can be effectively improved through the proper control of microstructure and internal defects.展开更多
A high-building multi-directional pipe joint(HBMDPJ)was fabricated by wire and arc additive manufacturing using high-strength low-alloy(HSLA)steel.The microstructure characteristics and transformation were observed an...A high-building multi-directional pipe joint(HBMDPJ)was fabricated by wire and arc additive manufacturing using high-strength low-alloy(HSLA)steel.The microstructure characteristics and transformation were observed and analyzed.The results show that the forming part includes four regions.The solidification zone solidifies as typical columnar crystals from a molten pool.The complete austenitizing zone forms from the solidification zone heated to a temperature greater than 1100℃,and the typical columnar crystals in this zone are difficult to observe.The partial austenitizing zone forms from the completely austenite zone heated between Ac1(austenite transition temperature)and1100℃,which is mainly equiaxed grains.After several thermal cycles,the partial austenitizing zone transforms to the tempering zone,which consistes of fully equiaxed grains.From the solidification zone to the tempering zone,the average grain size decreases from 75 to20μm.The mechanical properties of HBMDPJ satisfies the requirement for the intended application.展开更多
Wire arc additive manufacturing(WAAM)is a novel manufacturing technique by which high strength metal components can be fabricated layer by layer using an electric arc as the heat source and metal wire as feedstock,and...Wire arc additive manufacturing(WAAM)is a novel manufacturing technique by which high strength metal components can be fabricated layer by layer using an electric arc as the heat source and metal wire as feedstock,and offers the potential to produce large dimensional structures at much higher build rate and minimum waste of raw material.In the present work,a cold metal transfer(CMT)based additive manufacturing was carried out and the effect of deposition rate on the microstructure and mechanical properties of WAAM Ti-6Al-4V components was investigated.The microstructure of WAAM components showed similar microstructural morphology in all deposition conditions.When the deposition rate increased from 1.63 to 2.23 kg/h,the ultimate tensile strength(UTS)decreased from 984.6 MPa to 899.2 MPa and the micro-hardness showed a scattered but clear decline trend.展开更多
Magnesium(Mg)alloys,as the lightest metal structural material with good damping capacities,have im-portant application prospects in realizing structural lightweight and vibration reduction.However,their engineering ap...Magnesium(Mg)alloys,as the lightest metal structural material with good damping capacities,have im-portant application prospects in realizing structural lightweight and vibration reduction.However,their engineering application is greatly limited by poor plastic formability.Wire and arc additive manufactur-ing(WAAM)provides a potential approach for fabricating large-scale Mg alloy components with high manufacturing flexibility.In this study,the evolution of the solidification microstructure of a WAAM-processed Mg-Al-based alloy was quantitatively analyzed based on the analytical models;then,the cor-relations between the solidification microstructure and mechanical properties/damping capacities were investigated.The results revealed that the WAAM-processed Mg-Al-based alloy with an equiaxed-grain-dominated microstructure displayed a simultaneous enhancement in mechanical properties and damping capacities compared to those of the cast Mg-Al-based alloy.The good combination of mechanical prop-erties and damping capacities are mainly attributed to the weakened basal texture with a relatively high Schmid factor for basalslip,the twinning-induced plasticity(TWIP)effect associated with the profuse{10-12}tensile twinning,and the relatively high dislocation density caused by the thermal stress during the WAAM process.展开更多
Realizing improved strength in composite metallic materials remains a challenge using conventional welding and joining systems due to the generation and development of brittle intermetallic compounds caused by complex...Realizing improved strength in composite metallic materials remains a challenge using conventional welding and joining systems due to the generation and development of brittle intermetallic compounds caused by complex thermal profiles during solidification.Here,wire arc additive manufacturing(WAAM)process was used to fabricate a steel-nickel structural component,whose average tensile strength of 634 MPa significantly exceeded that of feedstock materials(steel,537 MPa and nickel,455 MPa),which has not been reported previously.The as-fabricated sample exhibited hierarchically structural heterogeneity due to the interweaving deposition strategy.The improved mechanical response during tensile testing was due to the inter-locking microstructure forming a strong bond at the interface and solid solutions strengthening from the intermixing of the Fe and Ni increased the interface strength,beyond the sum of parts.The research offers a new route for producing high-quality steel-nickel dissimilar structures and widens the design opportunities of monolithic components,with site-specific properties,for specific structural or functional applications.展开更多
Cold metal transfer plus pulse(C+P)arc was applied in the additive manufacturing of 4043 Al alloy parts.Parameters in the manufacturing of the parts were investigated.The properties and microstructure of the parts wer...Cold metal transfer plus pulse(C+P)arc was applied in the additive manufacturing of 4043 Al alloy parts.Parameters in the manufacturing of the parts were investigated.The properties and microstructure of the parts were also characterized.Experimental results showed that welding at a speed of 8 mm/s and a wire feeding speed of 4.0 m/min was suitable to manufacture thin-walled parts,and the reciprocating scanning method could be adopted to manufacture thick-walled parts.The thin-walled parts of the C+P mode had fewer pores than those of the cold metal transfer(CMT)mode.The thin-and thick-walled parts of the C+P mode showed maximum tensile strengths of 172 and 178 MPa,respectively.Hardness decreased at the interface and in the coarse dendrite and increased in the refined grain area.展开更多
In the paper, the finite element model(FEM) of wire arc additive manufacturing(WAAM) by TIG method was established by the ABAQUS soft, and the phase transformation latent heat was considered in the model. The evolutio...In the paper, the finite element model(FEM) of wire arc additive manufacturing(WAAM) by TIG method was established by the ABAQUS soft, and the phase transformation latent heat was considered in the model. The evolution rules of temperature field at the interlayer with the cooling time of 10 s, 30 s and 50 s were obtained by the model. The WAAM experiment were performed by 5356 aluminum alloy welding wire with φ1.2 mm, and the simulated temperature field were varified by the thermocouple. The result shows that the highest temperature at the molten pool center increases with the increased interlayers at the same interlayer cooling time;the highest temperature drops gradually and the decline is smaller with the increased interlayer cooling time at the same layer. No remelting occurs at the top layer, and at least two remelting times occur in the other layers, resulting in complex temperature field evolution.展开更多
Numerous studies have addressed the advantages of wire arc additive manufacturing for manufacturing aluminum alloys. However, the role of Ti content in aluminum alloys has rarely been discussed. Herein, the effect of ...Numerous studies have addressed the advantages of wire arc additive manufacturing for manufacturing aluminum alloys. However, the role of Ti content in aluminum alloys has rarely been discussed. Herein, the effect of Ti content on the microstructure and properties of Al–7 Si–0.6 Mg alloys was studied. The alloys were deposited via wire arc additive manufacturing and were examined through optical microscopy(OM), scanning electron microscopy(SEM), and electronic universal testing. The results show that the increase of Ti content gradually promotes the increase of the secondary dendrite arm spacing and also has an increasing tendency to form pores defect in the as-deposited alloys. The change of titanium content also affects the difference between horizontal and vertical direction properties of the alloy. The alloy with a Ti content of 0.112 wt% exhibits the best comprehensive properties. There is no difference in its horizontal and vertical direction properties. The tensile strengths, yield strengths, and elongation of this alloy(T6) along the vertical and horizontal axis are 356 and 355 MPa, 307 and308 MPa, and 8.5% and 8.0%, respectively.展开更多
Based on wire arc additive manufacturing(WAAM)technology,AZ31 magnesium alloy in bulk was successfully fabricated,and its microstructure as well as mechanical properties in different planes were observed and analyzed....Based on wire arc additive manufacturing(WAAM)technology,AZ31 magnesium alloy in bulk was successfully fabricated,and its microstructure as well as mechanical properties in different planes were observed and analyzed.The AZ31 magnesium alloy has a similar microstructure in the building direction(Z)and travel direction(X),both of which are equiaxed grains.There are heat-affected zones(HAZs)with coarse grains below the fusion line.The second phase is primarily composed of the Mg17Al12 phase,which is evenly distributed in different directions.In addition,the residual stress varies in different directions.There is no significant difference in the hardness of the AZ31 alloy along the Z and X directions,with the average hardness being 68.4 HV and 67.9 HV,respectively.Even though the specimens’ultimate tensile strength along the travel direction is higher in comparison to that along the building direction,their differences in elongation and yield strength are smaller,indicating that the anisotropy of the mechanical properties of the material is small.展开更多
基金National Key Research and Development Program of China(2022YFB4600902)Shandong Provincial Science Foundation for Outstanding Young Scholars(ZR2024YQ020)。
文摘Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing additive-induced defects,and alleviating residual stress and deformation,all of which are critical for enhancing the mechanical performance of the manufactured parts.Integrating interlayer friction stir processing(FSP)into WAAM significantly enhances the quality of deposited materials.However,numerical simulation research focusing on elucidating the associated thermomechanical coupling mechanisms remains insufficient.A comprehensive numerical model was developed to simulate the thermomechanical coupling behavior in friction stir-assisted WAAM.The influence of post-deposition FSP on the coupled thermomechanical response of the WAAM process was analyzed quantitatively.Moreover,the residual stress distribution and deformation behavior under both single-layer and multilayer deposition conditions were investigated.Thermal analysis of different deposition layers in WAAM and friction stir-assisted WAAM was conducted.Results show that subsequent layer deposition induces partial remelting of the previously solidified layer,whereas FSP does not cause such remelting.Furthermore,thermal stress and deformation analysis confirm that interlayer FSP effectively mitigates residual stresses and distortion in WAAM components,thereby improving their structural integrity and mechanical properties.
基金supported in part by China Scholarship Council under Grant 202208200010。
文摘Wire arc additive manufacturing(WAAM)has emerged as a promising technique for producing large-scale metal components,favoured by high deposition rates,flexibility and low cost.Despite its potential,the complexity of WAAM processes,which involves intricate thermal dynamics,phase transitions,and metallurgical,mechanical,and chemical interactions,presents considerable challenges in final product qualities.Simulation technologies in WAAM have proven invaluable,providing accurate predictions in key areas such as material properties,defect identification,deposit morphology,and residual stress.These predictions play a critical role in optimising manufacturing strategies for the final product.This paper provides a comprehensive review of the simulation techniques applied in WAAM,tracing developments from 2013 to 2023.Initially,it analyses the current challenges faced by simulation methods in three main areas.Subsequently,the review explores the current modelling approaches and the applications of these simulations.Following this,the paper discusses the present state of WAAM simulation,identifying specific issues inherent to WAAM simulation itself.Finally,through a thorough review of existing literature and related analysis,the paper offers future perspectives on potential advancements in WAAM simulation strategies.
基金supported by the Frontier Technologies R&D Program of Jiangsu(Grant No.BF2024077)Key Research and Development Program of Jiangsu Province(Grant Nos.BE2022069–1,BE2022069–2)+2 种基金National Funded Postdoctoral Researcher Program(Grant No.GZC20240817)Shui Mu Tsinghua Scholar(Grant No.2024SM038)China Postdoctoral Science Foundation(2025M771345).
文摘Ti-6Al-4V(Ti64)alloys are widely used in the aerospace and automotive industries owing to their excellent high-temperature mechanical properties.This study investigated the creep behavior of Ti64 samples with ultra-lowβcontent(<1%)fabricated by wire arc additive manufacturing(WAAM)under high-temperature and high-stress conditions.The creep properties of the WAAM Ti64 samples were evaluated at 600°C and 700°C with different stresses,and they were analyzed using electron backscattered diffraction(EBSD)and transmission electron microscopy(TEM).Commercially forged Ti64 samples were used as controls to compare their microstructures.As the stress increased,the degree of recrystallization intensified,leading to finer recrystallized grains.After high-temperature deformation,theβcontent in WAAM samples increased from less than 1%to over 8%.The dislocation density was high at low deformations,and the degree of recrystallization was low,suggesting superior creep resistance of the WAAM samples.The stress exponent,EBSD,and TEM analyses confirmed that dislocation movement primarily governs creep deformation in WAAM Ti64.Conversely,the forged samples exhibited easier deformation,lower dislocation density,higher recrystallization,and inferior creep resistance.This research highlights the impact ofβcontent and microstructure on the creep behavior of Ti64.The WAAM Ti64 with ultra-lowβcontent demonstrates enhanced creep resistance compared to commercially forged samples,primarily due to its unique microstructure with closely interconnectedαphases and lowerβ-phase content.
基金The National Natural Science Foundations of China(Nos.52071191 and 52471080)are acknowledged for providing the financial support.
文摘Additive manufacturing(AM)technologies,with their high degree of flexibility,enhance material utilization in the fabrication of large magnesium alloy parts,effectively meeting the demands of complex geometries.However,research on the corrosion resistance of magnesium alloy components produced via AM is currently limited.This study investigates the microstructural and corrosion characteristics of AZ91D magnesium alloy fabricated by wire arc additive manufacturing(WAAM)compared to its cast counterpart.A large-sized AZ91D bulk part was deposited on an AZ31 base plate using a layer-by-layer stacking approach.The results showed that the WAAM AZ91D was featured by obviously refined grains from 228.92μm of the cast one to 52.92μm on the travel direction-through thickness(TD-TT)and 50.07μm on the normal direction-through thickness(ND-TT).The rapid solidification process of WAAM inhibited the formation of β-Mg_(17)Al_(12) phase while promoting the formation of uniformly distributed network of dislocations,the dispersive precipitation of nano Al_(8)Mn_(5) phase,as well as Zn segregation.WAAM AZ91D demonstrated the occurrence of pitting corrosion and inferior corrosion resistance compared to cast AZ91D,attributed to the micro-galvanic corrosion between the α-Mg matrix and Al_(8)Mn_(5) particles and the increased number of grain boundaries.
基金supported by the National Natural Science Foundation of China(No.52205360)。
文摘Owing to the lack of matching commercial welding wires,the development of wire arc additive manufacturing(WAAM)for most aluminum alloys is hindered.A wire-powder synchronous arc additive manufacturing(WPAAM)was proposed to prepare the target Al-Si-Mg aluminum alloy.Based on the synchronous deposition of AlSi_(12) wire and pure Mg powder,the deposition width of the WPAAMed thin-wall was increased by 61% compared with that of WAAMed thin-wall using AlSi_(12) wire,and the machining allowance was reduced by 81%.The added Mg powder benefited to form refined equiaxed grains,and reduced the average grain size of the WPAAMed thin-wall to 47.1μm,showing a decrease of 23.8% relatively to that of the WAAMed thin-wall.Besides,Mg reacted with Si to form Mg_(2)Si strengthening phases.The mechanical properties tests showed that the ultimate tensile strength and elongation of the WPAAMed thin-wall increased up to 174.5 MPa and 4.1%,reaching 92% and 60% those of the WAAMed thin-wall,respectively.
基金supported by the National Natural Science Foundation of China(Grant Nos.52001037,U2037601,and U21A2048)the Science and Technology Program of Guangzhou,China(Grant No.2022BLC003).
文摘Si-containing Mg alloys solidified at conventional rates often contain coarse and sharp Mg_(2)Si phases,which can result in inferior material properties.In this study,Mg-6wt.%Si(Mg-6Si)alloy was prepared by wire arc additive manufacturing(WAAM),employing the gas tungsten arc welding technique with rapid cooling.The microstructures and mechanical properties of the WAAM alloy were investigated and compared with those of the as-cast samples produced using a metal mold.The results indicate that the WAAM Mg-6Si is harder and stronger than the as-cast samples.The microhardness of the WAAM Mg-6Si increases by 36.6% in comparison to that of as-cast Mg-6Si alloy.Furthermore,the average tensile strengths at room temperature and 150℃ increases by 63.4% and 21.3%,respectively.WAAM refines both the Mg_(2)Si phase and the overall grains,resulting in a homogeneous morphology and improved mechanical properties.The granular Mg_(2)Si phase,characterized by fine particles with a diffused distribution,shows a significant increase in concentration.The acicular Mg_(2)Si phase is distributed along the grain boundaries,and its concentration significantly decreases.The average grain size of the Mg_(2)Si phase is about 9.20μm,about 5 times smaller.The refinement and distribution of the granular Mg_(2)Si phase,as well as the reduction in the amount of needle-like Mg_(2)Si particles,are the key factors for improving the mechanical properties of WAAM Mg-6Si alloy.
基金supported by the National Natural Science Foundation of China(52375372)the National Key Laboratory of Particle Transport and Separation Technology(KWKF-2024-3).
文摘Heterogeneous manufacturing is a topic that continues to receive attention.As an emerging manufacturing technology,additive manufacturing can provide strong technical support for heterogeneous manufacturing.In this study,both homogeneous and heterogeneous composite tubular bionic components were fabricated based on the cold metal transition technology,and the influence of deposition current on the microstructure and mechanical properties of the components was studied.The results show that the interface of the as-deposited heterogeneous composite component is well bonded,and there is an obvious mechanical interlocking structure.The compressive yield strength and elongation of the heterogeneous composite components are higher than those of the homogeneous components,and are positively correlated with the deposition current.Due to the fluctuation of element content,there are a large number of fine grain structures at the interface of the heterogeneous composite components,which increases the mechanical properties.
基金supported by the National Key Research and Development Program of China(No.2021YFB3701004)National Natural Science Foundation of China(No.52071211)Joint Research Center of Advanced Aerospace Technology of Shanghai Academy of Spaceflight Technology-Shanghai Jiao Tong University(No.USCAST2020-1).
文摘The Mg-Gd-Y-Zn-Zr(GWZ)alloy containing a long-period ordered stacking(LPSO)phase fabricated by Wire arc additive manufacturing(WAAM)shows substantial potential in the aerospace and automotive industries.In this work,Mg-9Gd-4Y-1Zn-0.4Zr(wt%)single-layer and multilayer components with high-forming-quality were fabricated using WAAM based on cold metal transfer(WAAM-CMT).The deposition parameters were optimized,achieving better deposition morphology and surface quality.The layer-by-layer cyclic microstructure includes remelting zone(RMZ)and non-remelting zone(NRZ),which consisted of α-Mg matrix,blocky LPSO phase,and eutectic phase.The average grain size were 26.8μm in RMZ and 39.3μm in NRZ,and the volume fraction of secondary phases was around 8%,remaining consistent across different layers.The coarse-fine-grain alternating structure generated hetero deformation induced(HDI)strengthening,while at the same time caused the fracture occurring between the NRZ and RMZ due to the weak interlayer bonding.The thermally stabilized blocky LPSO phase played an effective role on inhibiting grain growth during the solid-solution treatment.The specimen achieved highest isotropic mechanical properties after optimized heat treatment with yield strength,ultimate tensile strength,and elongation higher than 220 MPa,370 MPa,and 8.0%,respectively.The GWZ alloys fabricated by WAAM with great isotropic strength-ductility-synergy are promising candidates to replace the conventionally cast counterparts.
基金the National Natural Science Foundation of China(No.51975419)。
文摘Additive manufacturing is a very promising manufacturing method widely used in various industries.In this study,for the first time,a new type of combined cable wire(CCW)with multi-element composition has been designed and developed for arc additive manufacturing(AAM)of non-equiatomic Al-Co-Cr-FeNi high-entropy alloy.CCW composed of 7 filaments and 5 elements has the advantages of high deposition efficiency,self-rotation of welding arc and energy saving capability.Thin HEA walls were fabricated under pure argon gas using cold metal transfer technology.Microstructural observations of the developed HEA reveal(i)BCC and FCC phases,(ii)Good bonding between layers and(iii)defect-free microstructure.The developed alloy exhibits high compression strength(~2.8 GPa)coupled with high plastic strain(~42%)values(possess both strength and ductility).It has been identified that by varying the heat input via torch travel speed,the microstructure and mechanical properties of the HEA can be controlled.From this feasibility study,it has been proved that the innovative CCW method can be used to manufacture HEAs with CCW-AAM.Further,the study highlights the advantage of the rapid cooling involved in the CCW-AAM process which gives rise to superior mechanical properties.
基金financial supports from the National Natural Science Foundation of China(Nos.51875041,51875042)。
文摘A graded structural material(GSM)with a material transition from TA15 to TC11 was fabricated by wire arc additive manufacturing(WAAM)method.The grain morphology,chemical composition,microstructure and mechanical properties of the as-deposited GSM were all characterized to investigate their variations along the deposition direction.The results indicate that from TA15 to TC11,the grain size decreases and a transition from columnar grains to equiaxed grains occurs.The content of alloy element alters greatly within a short distance,and the width of the mutation zone is 800μm.Both TA15 and TC11 regions exhibit basketweave microstructure withα-phase andβ-phase.However,during the transition from TA15 to TC11,theα-lath becomes fine,which leads to an increase in microhardness.The tensile test shows that the bonding strength at the interface is higher than the longitudinal strength of TA15,and the lateral elongation at the interface is higher than that of TA15 and TC11.
基金the China Scholarship Council[grant numbers:201907000039],the National Key Research and Development Plan of China[grant number 2017YFB0305905]The authors acknowledge the financial support from the 2020 open projects[grant numbers:KLATM202003]of Key laboratory of Advanced Technologies of Materials,Ministry of Education China,Southwest Jiaotong University。
文摘To maximize the benefits of wire arc additive manufacturing(WAAM)processes,the effect of post-deposition heat treatment on the microstructure and mechanical properties of WAAM AZ80M magnesium(Mg)alloy was investigated.Three different heat treatment procedures(T4,T5 and T6)were performed.According to the results,after T4 heat treatment,the microsegregation of alloying elements was improved with the eutectic structure dissolved.Samples after T5 heat treatment inherited the net-like distribution of secondary phases similar to the as-deposited sample,where the eutectic structure covering the interdendritic regions and theβ-phase precipitated around the eutectic structure.After T6 heat treatment,the tinyβ-phases re-precipitated from the matrix and distributed in inner and outer of the grains.The hardness distribution of the samples went through T4 and T6 heat treatment was more uniform in comparison to that of T5 heat treated samples.The tensile test showed that the T6 heat treatment improved the strength and ductility,and the anisotropy between horizontal and vertical can be eliminated.Moreover,T4 treated samples exhibited highest ductility.
基金the National Natural Science Foundation of China(No.51805415)the China Postdoctoral Science Foundation(No.2019M663682)the Open Fund of the State Key Laboratory for Mechanical Behavior of Materials(No.20212311)。
文摘Aluminum alloy is the most widely used light alloy at present.By combining different types of aluminum alloys,their functional properties can be expanded.In the present research,two components composed of 2319(Al-6.5Cu)and 5B06(Al-6.4Mg)dissimilar alloys were fabricated by wire and arc additive manufacturing(WAAM).The deposited component with the bottom half of 2319 and the top half of 5B06 exhibits better mechanical properties than its counterpart deposited vice versa.Its ultimate tensile strength,yield strength,and elongation are 258.5 MPa,139.3 MPa,and 5.6%,respectively,which are only slightly inferior to the mechanical properties of 2319 base metal.The results show that for both components,fracture occurred at a layer thickness above the interface layer during the tensile test,regardless of the deposition order.It appears that the thermal stress due to the long dwell time and the remelting of the S-AlCu Mg phase are the main factors promoting crack initiation.Depending on the deposition order,cracks propagate either along the aggregated pores or stripθ-AlCu phase distributed along the grain boundary.By analyzing the heat input and selecting the appropriate depositing order,the strength of WAAM dissimilar aluminum alloys can be effectively improved through the proper control of microstructure and internal defects.
基金financially supported by the National Key R&D Program of China(No.2017YFB1103200)the Independent Innovation Research Fund Project of Huazhong University of Science and Technology(No.2018KFYXMPT002)。
文摘A high-building multi-directional pipe joint(HBMDPJ)was fabricated by wire and arc additive manufacturing using high-strength low-alloy(HSLA)steel.The microstructure characteristics and transformation were observed and analyzed.The results show that the forming part includes four regions.The solidification zone solidifies as typical columnar crystals from a molten pool.The complete austenitizing zone forms from the solidification zone heated to a temperature greater than 1100℃,and the typical columnar crystals in this zone are difficult to observe.The partial austenitizing zone forms from the completely austenite zone heated between Ac1(austenite transition temperature)and1100℃,which is mainly equiaxed grains.After several thermal cycles,the partial austenitizing zone transforms to the tempering zone,which consistes of fully equiaxed grains.From the solidification zone to the tempering zone,the average grain size decreases from 75 to20μm.The mechanical properties of HBMDPJ satisfies the requirement for the intended application.
基金Projects(52075317,51905333)supported by the National Natural Science Foundation of ChinaProject(IEC\NSFC\181278)supported by the Royal Society through International Exchanges 2018 Cost Share(China)Scheme+2 种基金Project(19YF1418100)supported by Shanghai Sailing Program,ChinaProjects(19511106400,19511106402)supported by Shanghai Science and Technology Committee Innovation,ChinaProject(19030501300)supported by Shanghai Local Colleges and Universities Capacity Building Special Plan,China。
文摘Wire arc additive manufacturing(WAAM)is a novel manufacturing technique by which high strength metal components can be fabricated layer by layer using an electric arc as the heat source and metal wire as feedstock,and offers the potential to produce large dimensional structures at much higher build rate and minimum waste of raw material.In the present work,a cold metal transfer(CMT)based additive manufacturing was carried out and the effect of deposition rate on the microstructure and mechanical properties of WAAM Ti-6Al-4V components was investigated.The microstructure of WAAM components showed similar microstructural morphology in all deposition conditions.When the deposition rate increased from 1.63 to 2.23 kg/h,the ultimate tensile strength(UTS)decreased from 984.6 MPa to 899.2 MPa and the micro-hardness showed a scattered but clear decline trend.
基金supported by the National Key Research and Development Program of China (No.2021YFB3701100)the National Natural Science Foundation of China (Nos.U20A20234,51874062)+1 种基金the Postdoctoral Science Foundation of China (No.2022M710503)the Chongqing Foundation and Advanced Research Project (No.cstc2019jcyj-zdxmX0010).
文摘Magnesium(Mg)alloys,as the lightest metal structural material with good damping capacities,have im-portant application prospects in realizing structural lightweight and vibration reduction.However,their engineering application is greatly limited by poor plastic formability.Wire and arc additive manufactur-ing(WAAM)provides a potential approach for fabricating large-scale Mg alloy components with high manufacturing flexibility.In this study,the evolution of the solidification microstructure of a WAAM-processed Mg-Al-based alloy was quantitatively analyzed based on the analytical models;then,the cor-relations between the solidification microstructure and mechanical properties/damping capacities were investigated.The results revealed that the WAAM-processed Mg-Al-based alloy with an equiaxed-grain-dominated microstructure displayed a simultaneous enhancement in mechanical properties and damping capacities compared to those of the cast Mg-Al-based alloy.The good combination of mechanical prop-erties and damping capacities are mainly attributed to the weakened basal texture with a relatively high Schmid factor for basalslip,the twinning-induced plasticity(TWIP)effect associated with the profuse{10-12}tensile twinning,and the relatively high dislocation density caused by the thermal stress during the WAAM process.
基金carried out at the Welding Engineering Research Group,University of Wollongong,and it was supported by China Scholarship Council(No.201506680056)the National Natural Science Foundation of China(No.51805085)。
文摘Realizing improved strength in composite metallic materials remains a challenge using conventional welding and joining systems due to the generation and development of brittle intermetallic compounds caused by complex thermal profiles during solidification.Here,wire arc additive manufacturing(WAAM)process was used to fabricate a steel-nickel structural component,whose average tensile strength of 634 MPa significantly exceeded that of feedstock materials(steel,537 MPa and nickel,455 MPa),which has not been reported previously.The as-fabricated sample exhibited hierarchically structural heterogeneity due to the interweaving deposition strategy.The improved mechanical response during tensile testing was due to the inter-locking microstructure forming a strong bond at the interface and solid solutions strengthening from the intermixing of the Fe and Ni increased the interface strength,beyond the sum of parts.The research offers a new route for producing high-quality steel-nickel dissimilar structures and widens the design opportunities of monolithic components,with site-specific properties,for specific structural or functional applications.
基金the National Natural Science Foundation of China(Nos.51605276 and51905333)Shanghai Sailing Program(No.19YF1418100)+2 种基金Shanghai Science and Technology Committee Innovation Grant(Nos.17JC1400600 and 17JC1400601)Karamay Science and Technology Major Project(No.2018ZD002B)Aid for Xinjiang Science and Technology Project(No2019E0235)。
文摘Cold metal transfer plus pulse(C+P)arc was applied in the additive manufacturing of 4043 Al alloy parts.Parameters in the manufacturing of the parts were investigated.The properties and microstructure of the parts were also characterized.Experimental results showed that welding at a speed of 8 mm/s and a wire feeding speed of 4.0 m/min was suitable to manufacture thin-walled parts,and the reciprocating scanning method could be adopted to manufacture thick-walled parts.The thin-walled parts of the C+P mode had fewer pores than those of the cold metal transfer(CMT)mode.The thin-and thick-walled parts of the C+P mode showed maximum tensile strengths of 172 and 178 MPa,respectively.Hardness decreased at the interface and in the coarse dendrite and increased in the refined grain area.
基金This work was supported by the National Natural Science Foundation of China(Grant No.51905423)Natural.Science Basic Research Plan in Shaanxi Province of China(Grant No.2021JM338)+1 种基金China Scholarship Council(Grant No.201908610042)Application Technology R&D Project of Beilin District(GX2102).
文摘In the paper, the finite element model(FEM) of wire arc additive manufacturing(WAAM) by TIG method was established by the ABAQUS soft, and the phase transformation latent heat was considered in the model. The evolution rules of temperature field at the interlayer with the cooling time of 10 s, 30 s and 50 s were obtained by the model. The WAAM experiment were performed by 5356 aluminum alloy welding wire with φ1.2 mm, and the simulated temperature field were varified by the thermocouple. The result shows that the highest temperature at the molten pool center increases with the increased interlayers at the same interlayer cooling time;the highest temperature drops gradually and the decline is smaller with the increased interlayer cooling time at the same layer. No remelting occurs at the top layer, and at least two remelting times occur in the other layers, resulting in complex temperature field evolution.
基金financially supported by the National Key R&D Program of China(No.2018YFB1106300-5)。
文摘Numerous studies have addressed the advantages of wire arc additive manufacturing for manufacturing aluminum alloys. However, the role of Ti content in aluminum alloys has rarely been discussed. Herein, the effect of Ti content on the microstructure and properties of Al–7 Si–0.6 Mg alloys was studied. The alloys were deposited via wire arc additive manufacturing and were examined through optical microscopy(OM), scanning electron microscopy(SEM), and electronic universal testing. The results show that the increase of Ti content gradually promotes the increase of the secondary dendrite arm spacing and also has an increasing tendency to form pores defect in the as-deposited alloys. The change of titanium content also affects the difference between horizontal and vertical direction properties of the alloy. The alloy with a Ti content of 0.112 wt% exhibits the best comprehensive properties. There is no difference in its horizontal and vertical direction properties. The tensile strengths, yield strengths, and elongation of this alloy(T6) along the vertical and horizontal axis are 356 and 355 MPa, 307 and308 MPa, and 8.5% and 8.0%, respectively.
基金support from the International Science and Technology Cooperation Program of Shaanxi Province(No.2023-GHZD-50)Projects of Major Innovation Platforms for Scientific and Technological and Local Transformation of Scientific and Technological Achievements of Xi'an(No.20GXSF0003)+1 种基金Projects of Major Scientific and Technological Achievements Local Transformation of Xi'an(No.2022JH-ZDZH-0039)the Higher Education Institution Discipline Innovation and Intelligence Base of Shaanxi Province(No.S2021-ZCGXYZ-0011).
文摘Based on wire arc additive manufacturing(WAAM)technology,AZ31 magnesium alloy in bulk was successfully fabricated,and its microstructure as well as mechanical properties in different planes were observed and analyzed.The AZ31 magnesium alloy has a similar microstructure in the building direction(Z)and travel direction(X),both of which are equiaxed grains.There are heat-affected zones(HAZs)with coarse grains below the fusion line.The second phase is primarily composed of the Mg17Al12 phase,which is evenly distributed in different directions.In addition,the residual stress varies in different directions.There is no significant difference in the hardness of the AZ31 alloy along the Z and X directions,with the average hardness being 68.4 HV and 67.9 HV,respectively.Even though the specimens’ultimate tensile strength along the travel direction is higher in comparison to that along the building direction,their differences in elongation and yield strength are smaller,indicating that the anisotropy of the mechanical properties of the material is small.
