The z-axis-inclined 3D printing process using short carbon fiber-reinforced thermoplastic composites offers the potential for the support-free fabrication of complex structures and theoretically unlimited extension of...The z-axis-inclined 3D printing process using short carbon fiber-reinforced thermoplastic composites offers the potential for the support-free fabrication of complex structures and theoretically unlimited extension of printed components.It has emerged as a promising approach for in-orbit manufacturing of high-performance thermoplastic composite truss structures.However,extreme conditions of the space environment,such as high vacuum and fluctuating high-low temperatures,significantly alter the heat-transfer behavior during the printing process,often resulting in dimensional inaccuracies and degraded mechanical performance.Existing process optimization strategies fail to account for the coupled effects of vacuum and thermal extremes,limiting their applicability in guiding process design under varying vacuum temperature conditions.To address this gap,this study establishes a truss3D printing experimental platform with in situ temperature-monitoring capability under ground-simulated space conditions.It systematically investigates the effects of printing speed and structural geometry on the pre-bonding surface temperature and forming quality of truss structures in high-low temperature vacuum environments.This study reveals the mechanism by which processing and structural parameters affect the component performance through their influence on the pre-bonding surface temperature and dimensional accuracy.The experimental results show that under high-temperature vacuum conditions,the pre-bonding surface temperature is relatively high,resulting in good interfacial bonding.However,increasing the printing speed reduces the forming accuracy and leads to a decline in mechanical performance.In contrast,under low-temperature vacuum conditions,where the pre-bonding surface temperatures are lower,increasing the printing speed within a specific range effectively increases the surface temperature and bonding quality,thereby improving mechanical properties.Additionally,owing to frequent path transitions,the diagonal-strut truss exhibits a lower forming accuracy and pre-bonding surface temperature than the infilling truss,resulting in inferior mechanical performance in high-low temperature vacuum environments.展开更多
Baozhu sand particles with size between 75μm and 150μm were coated by resin with the ratio of 1.5 wt.%of sands.Laser sintering experiments were carried out to investigate the effects of laser energy density(E=P/v),w...Baozhu sand particles with size between 75μm and 150μm were coated by resin with the ratio of 1.5 wt.%of sands.Laser sintering experiments were carried out to investigate the effects of laser energy density(E=P/v),with different laser power(P)and scanning velocity(v),on the dimensional accuracy and tensile strength of sintered parts.The experimental results indicate that with the constant scanning velocity,the tensile strength of sintered samples increases with an increase in laser energy density;while the dimensional accuracy apparently decreases when the laser energy density is larger than 0.032 J·mm-2.When the laser energy density is 0.024 J·mm-2,the tensile strength shows no obvious change;but when the laser energy density is larger than 0.024 J·mm-2,the sample strength is featured by the initial increase and subsequent decrease with simultaneous increase of both laser power and scanning velocity.In this study,the optimal energy density range for laser sintering is 0.024-0.032 J·mm-2.Moreover,samples with the best tensile strength and dimensional accuracy can be obtained when P=30-40 W and v=1.5-2.0 m·s-1.Using the optimized laser energy density,laser power and scanning speed,a complex coated sand mould with clear contour and excellent forming accuracy has been successfully fabricated.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
To meet the evolving demands of aeroengine development,the structural and performance requirements for ceramic cores have become increasingly stringent.Vat photopolymerization 3D printing,owing to its moldless,fiexibl...To meet the evolving demands of aeroengine development,the structural and performance requirements for ceramic cores have become increasingly stringent.Vat photopolymerization 3D printing,owing to its moldless,fiexible manufacturing,and other advantages,demonstrates significant potential in the preparation of ceramic cores with intricate structures.However,its practical application still faces multiple challenges,including layered structures and property anisotropy,defects such as cracks and collapse during printing and sintering,forming inaccuracies,and difficulties in controlling surface roughness.Recent advances have focused on optimizing slurry formulation and rheology,improving curing behavior,introducing auxiliary powders and additives,tailoring forming parameters,and optimizing the sintering process.Nevertheless,effectively suppressing lamellar defects,achieving superior dimensional accuracy,and maintaining high surface quality in complex structures remain the core scientific and technical issues to be solved.Future research should concentrate on refining curing mechanisms,advancing powder design and organic system optimization,and regulating the coupled processes of forming,debinding,and sintering to accelerate the application of VPP 3D printed ceramic cores in aerospace manufacturing.展开更多
The aim of this work is to simulate thermal deformation of tool system and investigate the influence of cutting parameters on it in single-point diamond turning(SPDT) of aluminum alloy. The experiments with various cu...The aim of this work is to simulate thermal deformation of tool system and investigate the influence of cutting parameters on it in single-point diamond turning(SPDT) of aluminum alloy. The experiments with various cutting parameters were conducted. Cutting temperature was measured by FLIR A315 infrared thermal imager. Tool wear was measured by scanning electron microscope(SEM). The numerical model of heat flux considering tool wear generated in cutting zone was established. Then two-step finite element method(FEM) simulations matching the experimental conditions were carried out to simulate the thermal deformation. In addition, the tests of deformation of tool system were performed to verify previous simulation results. And then the influence of cutting parameters on thermal deformation was investigated. The results show that the temperature and thermal deformation from simulations agree well with the results from experiments in the same conditions. The maximum thermal deformation of tool reaches to 7 μm. The average flank wear width and cutting speed are the dominant factors affecting thermal deformation, and the effective way to decrease the thermal deformation of tool is to control the tool wear and the cutting speed.展开更多
基金supported by National Key Research and Development Program of China(Grant No.2023YFB4605301)the National Natural Science Foundation of China(Grant No.52130506)。
文摘The z-axis-inclined 3D printing process using short carbon fiber-reinforced thermoplastic composites offers the potential for the support-free fabrication of complex structures and theoretically unlimited extension of printed components.It has emerged as a promising approach for in-orbit manufacturing of high-performance thermoplastic composite truss structures.However,extreme conditions of the space environment,such as high vacuum and fluctuating high-low temperatures,significantly alter the heat-transfer behavior during the printing process,often resulting in dimensional inaccuracies and degraded mechanical performance.Existing process optimization strategies fail to account for the coupled effects of vacuum and thermal extremes,limiting their applicability in guiding process design under varying vacuum temperature conditions.To address this gap,this study establishes a truss3D printing experimental platform with in situ temperature-monitoring capability under ground-simulated space conditions.It systematically investigates the effects of printing speed and structural geometry on the pre-bonding surface temperature and forming quality of truss structures in high-low temperature vacuum environments.This study reveals the mechanism by which processing and structural parameters affect the component performance through their influence on the pre-bonding surface temperature and dimensional accuracy.The experimental results show that under high-temperature vacuum conditions,the pre-bonding surface temperature is relatively high,resulting in good interfacial bonding.However,increasing the printing speed reduces the forming accuracy and leads to a decline in mechanical performance.In contrast,under low-temperature vacuum conditions,where the pre-bonding surface temperatures are lower,increasing the printing speed within a specific range effectively increases the surface temperature and bonding quality,thereby improving mechanical properties.Additionally,owing to frequent path transitions,the diagonal-strut truss exhibits a lower forming accuracy and pre-bonding surface temperature than the infilling truss,resulting in inferior mechanical performance in high-low temperature vacuum environments.
基金financially supported by the National Defence Key Discipline Laboratory of Light Alloy Processing Science and Technology,Aeronautical Science Foundation of China(Grant No.2011ZE56007)the Natural Science Foundation of Jiangxi Province(Grant No.2010GZC0159)the High Technology Landing Program of Jiangxi University(Grant No.DB201303014)
文摘Baozhu sand particles with size between 75μm and 150μm were coated by resin with the ratio of 1.5 wt.%of sands.Laser sintering experiments were carried out to investigate the effects of laser energy density(E=P/v),with different laser power(P)and scanning velocity(v),on the dimensional accuracy and tensile strength of sintered parts.The experimental results indicate that with the constant scanning velocity,the tensile strength of sintered samples increases with an increase in laser energy density;while the dimensional accuracy apparently decreases when the laser energy density is larger than 0.032 J·mm-2.When the laser energy density is 0.024 J·mm-2,the tensile strength shows no obvious change;but when the laser energy density is larger than 0.024 J·mm-2,the sample strength is featured by the initial increase and subsequent decrease with simultaneous increase of both laser power and scanning velocity.In this study,the optimal energy density range for laser sintering is 0.024-0.032 J·mm-2.Moreover,samples with the best tensile strength and dimensional accuracy can be obtained when P=30-40 W and v=1.5-2.0 m·s-1.Using the optimized laser energy density,laser power and scanning speed,a complex coated sand mould with clear contour and excellent forming accuracy has been successfully fabricated.
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 Key R&D Program of China(Grant Nos.2024YFB3714502,2024YFB3714501,2024YFB3714504)the National Natural Science Foundation of China(Grant Nos.52130204,52174376)+5 种基金the TQ Innovation Foundation(Grant No.23-TQ09-02-ZT-01-005)the Aeronautical Science Foundation of China(Grant No.20220042053001)the Ningbo Science and Technology Plan Project(Grant No.2025Z070)the Key R&D Project of Shaanxi Province(Grant Nos2024GX-YBXM-220,2024CY-GJHX-29,2024GX-ZDCYL-03-03,2024GX-YBXM-400)the National Advanced Rare Metal Materials Innovation Center Project[Grant No.2024 ZG-GCZX-01(1)-01]the Foundation of China Scholarship Council(Grant No.202406290136)。
文摘To meet the evolving demands of aeroengine development,the structural and performance requirements for ceramic cores have become increasingly stringent.Vat photopolymerization 3D printing,owing to its moldless,fiexible manufacturing,and other advantages,demonstrates significant potential in the preparation of ceramic cores with intricate structures.However,its practical application still faces multiple challenges,including layered structures and property anisotropy,defects such as cracks and collapse during printing and sintering,forming inaccuracies,and difficulties in controlling surface roughness.Recent advances have focused on optimizing slurry formulation and rheology,improving curing behavior,introducing auxiliary powders and additives,tailoring forming parameters,and optimizing the sintering process.Nevertheless,effectively suppressing lamellar defects,achieving superior dimensional accuracy,and maintaining high surface quality in complex structures remain the core scientific and technical issues to be solved.Future research should concentrate on refining curing mechanisms,advancing powder design and organic system optimization,and regulating the coupled processes of forming,debinding,and sintering to accelerate the application of VPP 3D printed ceramic cores in aerospace manufacturing.
基金Project(51175122)supported by the National Natural Science Foundation of China
文摘The aim of this work is to simulate thermal deformation of tool system and investigate the influence of cutting parameters on it in single-point diamond turning(SPDT) of aluminum alloy. The experiments with various cutting parameters were conducted. Cutting temperature was measured by FLIR A315 infrared thermal imager. Tool wear was measured by scanning electron microscope(SEM). The numerical model of heat flux considering tool wear generated in cutting zone was established. Then two-step finite element method(FEM) simulations matching the experimental conditions were carried out to simulate the thermal deformation. In addition, the tests of deformation of tool system were performed to verify previous simulation results. And then the influence of cutting parameters on thermal deformation was investigated. The results show that the temperature and thermal deformation from simulations agree well with the results from experiments in the same conditions. The maximum thermal deformation of tool reaches to 7 μm. The average flank wear width and cutting speed are the dominant factors affecting thermal deformation, and the effective way to decrease the thermal deformation of tool is to control the tool wear and the cutting speed.
