电弧熔丝增材制造铝合金零件中气孔的研究现状
Research Status on Pore in Aluminum Alloy Parts by Wireand Arc Additive Manufacturing
摘 要
电弧熔丝增材制造铝合金中的气孔会产生应力集中，导致初始裂纹萌生和扩展，造成力学性能变差。介绍了电弧熔丝增材制造铝合金零件中气孔缺陷形成的原因，阐述了保护气体、焊接速度、送丝速度、金属丝材、热输入、轧制和热处理等工艺条件对气孔率的影响，并对降低电弧熔丝增材制造铝合金零件中气孔率的今后研究方向进行了展望。
铝合金
气孔
氢
wire and arc additive manufacturing
aluminum alloy
pore
hydrogen
Abstract
The stress concentration generated by the pores in aluminum alloy by wire and arc additive manufacturing leads to the initiation and propagation of initial cracks, resulting in the deterioration of mechanical properties. The porosity formation cause of aluminum alloy parts by wire and arc additive manufacturing is introduced. The effects of shielding gas, welding speed, wire feeding speed, metal wire material, heat input, rolling and heat treatment on porosity are described. The future research direction of reducing porosity in aluminum alloy parts by wire and arc additive manufacturing is prospected.
中图分类号 TG661 DOI 10.11973/jxgccl202111017
所属栏目 专题报道(增材制造)
基金项目 上海市大学生创新活动计划项目（202010259097）
收稿日期 2020/11/23
修改稿日期 2021/10/20
网络出版日期
作者单位点击查看
备注聂文忠(1971-),男,江西高安人,副教授,博士
引用该论文: NIE Wenzhong,ZENG Jiayi,LI Xiaoxuan,QIU Weihao. Research Status on Pore in Aluminum Alloy Parts by Wireand Arc Additive Manufacturing[J]. Materials for mechancial engineering, 2021, 45(11): 97～102
聂文忠,曾嘉艺,李晓萱,邱渭濠. 电弧熔丝增材制造铝合金零件中气孔的研究现状[J]. 机械工程材料, 2021, 45(11): 97～102
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参考文献
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【2】张波, 方志刚, 李向阳, 等.铝合金船舶的腐蚀防护技术现状与展望[J]. 中国材料进展, 2014, 33(7):414-417. ZHANG B, FANG Z G, LI X Y, et al. Status and prospect of corrosion protection technology about aluminium alloy ship[J]. Materials China, 2014, 33(7):414-417.
【3】洪腾蛟, 董福龙, 丁凤娟, 等.铝合金在汽车轻量化领域的应用研究[J]. 热加工工艺, 2020, 49(4):1-6. HONG T J, DONG F L, DING F J, et al. Application of aluminum alloy in automotive lightweight[J]. Hot Working Technology, 2020, 49(4):1-6.
【4】URIONDO A, ESPERON-MIGUEZ M, PERINPANAYAGAM S.The present and future of additive manufacturing in the aerospace sector:A review of important aspects[J]. Proceedings of the Institution of Mechanical Engineers, Part G:Journal of Aerospace Engineering, 2015, 229(11):2132-2147.
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【6】ZHANG Y B, XU J H, ZHAI T G.Distributions of pore size and fatigue weak link strength in an A713 sand cast aluminum alloy[J]. Materials Science and Engineering:A, 2010, 527(16/17):3639-3644.
【7】MAYER H, PAPAKYRIACOU M, ZETTL B, et al. Influence of porosity on the fatigue limit of die cast magnesium and aluminium alloys[J]. International Journal of Fatigue, 2003, 25(3):245-256.
【8】BOEIRA A P, FERREIRA I L, GARCIA A.Alloy composition and metal/mold heat transfer efficiency affecting inverse segregation and porosity of as-cast Al-Cu alloys[J]. Materials & Design, 2009, 30(6):2090-2098.
【9】ANYALEBECHI P N.Hydrogen-induced gas porosity formation in Al-4.5 wt% Cu-1.4 wt% Mg alloy[J]. Journal of Materials Science, 2013, 48(15):5342-5353.
【10】DA SILVA C L M, SCOTTI A.The influence of double pulse on porosity formation in aluminum GMAW[J]. Journal of Materials Processing Technology, 2006, 171(3):366-372.
【11】KAUFMAN J G, ROOY E L.Aluminum alloy castings[M].[S.l.]:ASM International, 2004.
【12】GU J L, WANG X S, BAI J, et al. Deformation microstructures and strengthening mechanisms for the wire+arc additively manufactured Al-Mg4.5Mn alloy with inter-layer rolling[J]. Materials Science and Engineering:A, 2018, 712:292-301.
【13】GENG H B, LI J L, XIONG J T, et al. Geometric limitation and tensile properties of wire and arc additive manufacturing 5A06 aluminum alloy parts[J]. Journal of Materials Engineering and Performance, 2017, 26(2):621-629.
【14】GU J L, DING J L, WILLIAMS S W, et al. The strengthening effect of inter-layer cold working and post-deposition heat treatment on the additively manufactured Al-6.3Cu alloy[J]. Materials Science and Engineering:A, 2016, 651:18-26.
【15】WILLIAMS S W, MARTINA F, ADDISON A C, et al. Wire + arc additive manufacturing[J]. Materials Science and Technology, 2016, 32(7):641-647.
【16】PANCHENKO O, KURUSHKIN D, MUSHNIKOV I, et al. A high-performance WAAM process for Al-Mg-Mn using controlled short-circuiting metal transfer at increased wire feed rate and increased travel speed[J]. Materials & Design, 2020, 195:109040.
【17】MIAO Q Y, WU D J, CHAI D S, et al. Comparative study of microstructure evaluation and mechanical properties of 4043 aluminum alloy fabricated by wire-based additive manufacturing[J]. Materials & Design, 2020, 186:108205.
【18】SU C C, CHEN X Z, GAO C, et al. Effect of heat input on microstructure and mechanical properties of Al-Mg alloys fabricated by WAAM[J]. Applied Surface Science, 2019, 486:431-440.
【19】SUN R J, LI L H, ZHU Y, et al. Microstructure, residual stress and tensile properties control of wire-arc additive manufactured 2319 aluminum alloy with laser shock peening[J]. Journal of Alloys and Compounds, 2018, 747:255-265.
【20】LI S, ZHANG L J, NING J, et al. Comparative study on the microstructures and properties of wire+arc additively manufactured 5356 aluminium alloy with argon and nitrogen as the shielding gas[J]. Additive Manufacturing, 2020, 34:101206.
【21】DING J, COLEGROVE P, MARTINA F, et al. Development of a laminar flow local shielding device for wire + arc additive manufacture[J]. Journal of Materials Processing Technology, 2015, 226:99-105.
【22】许良红, 田志凌, 张晓牧, 等.保护气体对高强铝合金的焊缝组织及气孔敏感性的影响[J]. 焊接学报, 2006, 27(12):69-73. XU L H, TIAN Z L, ZHANG X M, et al. Effects of shielding gas on microstructure and number of gas pore in high strength aluminum alloys weld[J]. Transactions of the China Welding Institution, 2006, 27(12):69-73.
【23】NUÑEZ E E N, UNFRIED SILGADO J, TORRES SALCEDO J E, et al. Influence of gas mixtures Ar-He and Ar-He-O2 on weldability of aluminum alloy AA5083-O using automated GMAW-P[J]. Welding International, 2016, 30(6):423-431.
【24】JURI AĆG I, GARA AŠG I AĆG I, BU AŠG I AĆG M, et al. Influence of shielding gas composition on structure and mechanical properties of wire and arc additive manufactured inconel 625[J]. JOM, 2019, 71(2):703-708.
【25】RYAN E M, SABIN T J, WATTS J F, et al. The influence of build parameters and wire batch on porosity of wire and arc additive manufactured aluminium alloy 2319[J]. Journal of Materials Processing Technology, 2018, 262:577-584.
【26】GU J L, DING J L, CONG B Q, et al. The influence of wire properties on the quality and performance of Wire+Arc additive manufactured aluminium parts[J]. Advanced Materials Research, 2014, 1081:210-214.
【27】ANYALEBECHI P N.Analysis of the effects of alloying elements on hydrogen solubility in liquid aluminum alloys[J]. Scripta Metallurgica et Materialia, 1995, 33(8):1209-1216.
【28】TODA H, HIDAKA T, KOBAYASHI M, et al. Growth behavior of hydrogen micropores in aluminum alloys during high-temperature exposure[J]. Acta Materialia, 2009, 57(7):2277-2290.
【29】CONG B Q, QI Z W, QI B J, et al. A comparative study of additively manufactured thin wall and block structure with Al-6.3%Cu alloy using cold metal transfer process[J]. Applied Sciences, 2017, 7(3):275.
【30】AZANAS P, DEHERKAR P, ALMEIDA P, et al. Fabrication of geometrical features using wire and arc additive manufacture[J]. Proceedings of the Institution of Mechanical Engineers, Part B:Journal of Engineering Manufacture, 2012, 226(6):1042-1051.
【31】ZHOU Y H, LIN X, KANG N, et al. Influence of travel speed on microstructure and mechanical properties of wire + arc additively manufactured 2219 aluminum alloy[J]. Journal of Materials Science & Technology, 2020, 37:143-153.
【32】WANG P, HU S S, SHEN J Q, et al. Characterization the contribution and limitation of the characteristic processing parameters in cold metal transfer deposition of an Al alloy[J]. Journal of Materials Processing Technology, 2017, 245:122-133.
【33】JIANG G R, LIU Y, LI Y X.A model for calculating hydrogen solubility in molten aluminum alloys[J]. Acta Metallurgica Sinica, 2008, 44(2):129-133.
【34】DEREKAR K S, ADDISON A, JOSHI S S, et al. Effect of pulsed metal inert gas (pulsed-MIG) and cold metal transfer (CMT) techniques on hydrogen dissolution in wire arc additive manufacturing (WAAM) of aluminium[J]. The International Journal of Advanced Manufacturing Technology, 2020, 107(1/2):311-331.
【35】KOU S, LE Y. Nucleation mechanism and grain refining of weld metal[J]. Welding Journal, 1986, 65(12):65-70.
【36】YUNJIA H, FROST R H, OLSON D L, et al. Grain refinement of aluminum weld metal[J]. Welding Research Supplement, 1989, 7:280-289.
【37】GUO X M, YAND C G, QIAN B N, et al. Effects of inoculants Ti and Zr on the microstructures and properties of 2219 Al-Cu alloy welds[J]. Acta Metall Sinica, 2005, 41(4):397-401.
【38】LI K D, CHANG E.Mechanism of nucleation and growth of hydrogen porosity in solidifying A356 aluminum alloy:An analytical solution[J]. Acta Materialia, 2004, 52(1):219-231.
【39】WANG S, GU H M, WANG W, et al. The influence of heat input on the microstructure and properties of wire-arc-additive-manufactured Al-Cu-Sn alloy deposits[J]. Metals, 2020, 10(1):79.
【40】WANG D H, LU J P, TANG S Y, et al. Reducing porosity and refining grains for arc additive manufacturing aluminum alloy by adjusting arc pulse frequency and current[J]. Materials, 2018, 11(8):1344.
【41】WU Q R, MA Z S, CHEN G S, et al. Obtaining fine microstructure and unsupported overhangs by low heat input pulse arc additive manufacturing[J]. Journal of Manufacturing Processes, 2017, 27:198-206.
【42】CONG B Q, DING J L, WILLIAMS S.Effect of arc mode in cold metal transfer process on porosity of additively manufactured Al-6.3%Cu alloy[J]. The International Journal of Advanced Manufacturing Technology, 2015, 76(9/10/11/12):1593-1606.
【43】PAL K, PAL S K.Effect of pulse parameters on weld quality in pulsed gas metal arc welding:A review[J]. Journal of Materials Engineering and Performance, 2011, 20(6):918-931.
【44】HARWIG D D, DIERKSHEIDE J E, YAPP D, et al. Arc behavior and melting rate in the VP-GMAW process[J]. Welding Journal, 2006, 85(3):52-62.
【45】AYARKWA K F, WILLIAMS S, DING J.Investigation of pulse advance cold metal transfer on aluminium wire arc additive manufacturing[J]. International Journal of Rapid Manufacturing, 2015, 5(1):44.
【46】GU J L, DING J L, WILLIAMS S W, et al. The effect of inter-layer cold working and post-deposition heat treatment on porosity in additively manufactured aluminum alloys[J]. Journal of Materials Processing Technology, 2016, 230:26-34.
【47】BOND G M, ROBERTSON I M, BIRNBAUM H K.The influence of hydrogen on deformation and fracture processes in high-strength aluminum alloys[J]. Acta Metallurgica, 1987, 35(9):2289-2296.
【48】ALBRECHT J, BERNSTEIN I M, THOMPSON A W.Evidence for dislocation transport of hydrogen in aluminum[J]. Metallurgical Transactions A, 1982, 13(5):811-820.
【49】TODA H, MINAMI K, KOYAMA K, et al. Healing behavior of preexisting hydrogen micropores in aluminum alloys during plastic deformation[J]. Acta Materialia, 2009, 57(15):4391-4403.
【50】FIXTER J, GU J, DING J, et al. Preliminary investigation into the suitability of 2xxx alloys for wire-arc additive manufacturing[J]. Materials Science Forum, 2016, 877:611-616.
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