电弧增材制造传热传质数值模拟技术综述

doi:10.11896/cldb.22090175

材料导报

2024, Vol. 38

Issue (9): 22090175-7 https://doi.org/10.11896/cldb.22090175

金属与金属基复合材料

电弧增材制造传热传质数值模拟技术综述

郭鑫鑫¹, 魏正英^1,*, 张永恒¹, 张帅锋^1,2

1 西安交通大学精密微纳制造技术全国重点实验室,西安 710049
2 中国船舶集团有限公司第七二五研究所,河南洛阳 471039

An Overview of Numerical Simulation of Heat and Mass Transfer in Wire Arc Additive Manufacturing

GUO Xinxin¹, WEI Zhengying^1,*, ZHANG Yongheng¹, ZHANG Shuaifeng^1,2

1 State Key Laboratory for Manufacturing Systems Engineering, Xi'an Jiaotong University, Xi'an 710049, China
2 Luoyang Ship Material Research Institute, Luoyang 471039, Henan, China

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摘要电弧增材制造过程涉及丝材的送入和熔化,熔融金属向熔池的过渡,熔池中液态金属的对流、凝固和成形。缺陷的形成与电弧增材制造过程中发生的复杂多物理场现象密切相关。因此,需要借助高保真数值模拟技术来深入理解这些物理现象,并将其作为优化工艺条件、制造高质量产品的理论依据。本文综述了电弧增材制造传热传质数值模拟涉及的关键技术,并对未来研究方向进行了展望:首先,介绍了几种典型的热源模型,鉴于电弧增材制造过程中熔池的形成与演变是多种驱动力共同作用的结果,分析了浮力、电磁力、表面张力、电弧压力、电弧剪应力模型对流体流动和熔池表面变形的影响;然后,总结了三种金属过渡模型,包括速度入口填充液态金属、指定位置添加球状质量源项以及直接建立固态金属焊丝;最后,介绍了常用的气液界面跟踪方法。

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	郭鑫鑫
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关键词: 电弧增材制造传热传质数值模拟熔池行为

Abstract: The wire arc additive manufacturing (WAAM) process involves the feeding and melting of wire, the transition of metal to a molten pool, the convection of liquid metal within the pool, and solidification. Defects may arise due to the complex, multi-physics nature of the process. Therefore, it is necessary to comprehend these physical phenomena through high-fidelity numerical simulations to establish a theoretical foundation for optimizing process conditions and producing high-quality products. This paper provides a comprehensive review of the key technologies involved in the numerical modeling of heat and mass transfer within WAAM and offers an outlook on potential future research directions. First, an overview of various heat source models is presented. Given that the formation and evolution of the molten pool in the WAAM is influenced by multiple driving forces, an analysis of buoyancy, electromagnetic force, surface tension, arc pressure, and arc shear stress is conducted. The impact of these models on fluid flow and surface deformation of the molten pool is evaluated. Subsequently, three metal transition models are summarized, including utilizing a velocity inlet filled with liquid metal, incorporating a spherical mass source term at a designated position, and establishing a solid metal welding wire directly. Finally, the commonly employed gas-liquid interface tracking method is introduced.

Key words: wire arc additive manufacturing heat and mass transfer numerical simulation molten pool behavior

出版日期: 2024-05-10 发布日期: 2024-05-13

ZTFLH:

TG444

基金资助: 应用创新项目;国家自然科学基金(52275376)

通讯作者: * 魏正英,西安交通大学机械与工程学院教授、博士研究生导师。主要研究方向为3D打印增材制造技术和灌溉施肥智能决测。已发表学术论文160余篇,其中63篇被SCI收录,50余篇被EI收录。其博士学位论文被评为2006年全国百篇优秀博士学位论文。申报专利76项,其中57项为发明专利(51项已授权)。获得的奖项包括2004年教育部提名国家技术发明一等奖,2005年国家技术发明二等奖,2006年教育部新世纪优秀人才,2008年陕西青年科技奖,2011年新疆生产建设兵团科学技术进步二等奖,2017年农科院杰出科技创新奖,以及2018年河南省科技进步一等奖。zywei@xjtu.edu.cn

作者简介: 郭鑫鑫,2021年1月于北京科技大学获得工学硕士学位。现为西安交通大学机械工程学院博士研究生,在魏正英教授的指导下进行研究。目前主要研究领域为电弧增材制造陶瓷颗粒增强金属基复合材料的相关基础理论与应用技术。

引用本文:

郭鑫鑫, 魏正英, 张永恒, 张帅锋. 电弧增材制造传热传质数值模拟技术综述[J]. 材料导报, 2024, 38(9): 22090175-7.
GUO Xinxin, WEI Zhengying, ZHANG Yongheng, ZHANG Shuaifeng. An Overview of Numerical Simulation of Heat and Mass Transfer in Wire Arc Additive Manufacturing. Materials Reports, 2024, 38(9): 22090175-7.

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http://www.mater-rep.com/CN/10.11896/cldb.22090175 或 http://www.mater-rep.com/CN/Y2024/V38/I9/22090175

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