Zhang Jun, Xing Yanfeng, Zhang Jijun, Cao Juyong, Yang Fuyong, Zhang Xiaobing
School of Mechanical and Automobile Engineering, Shanghai University of Engineering Science, Shanghai 201620, China.
Materials (Basel). 2022 Jul 26;15(15):5168. doi: 10.3390/ma15155168.
Wire and arc additive manufacturing (WAAM) is a competitive technique, which enables the fabrication of medium and large metallic components. However, due to the presence of coarse columnar grains in the additively manufactured parts, the resultant mechanical properties will be reduced, which limits the application of WAAM processes in the engineering fields. Grain refinement and improved mechanical properties can be achieved by introducing ultrasonic vibration. Herein, we applied ultrasonic vibration to the WAAM process and investigated the effects of wire feed speed, welding speed, and ultrasonic amplitude on the weld formation and grain size during ultrasonic vibration. Finally, a regression model between the average grain size and wire feed speed, welding speed, and ultrasonic amplitude was established. The results showed that due to the difference in heat input and cladding amount, wire feed speed, welding speed, and ultrasonic amplitude have a significant influence on the weld width and reinforcement. Excessive ultrasonic amplitude could cause the weld to crack during spreading. The average grain size increased with increasing wire feed speed and decreasing welding speed. With increasing ultrasonic amplitude, the average grain size exhibited a trend of decreasing first and then increasing. This would be helpful to manufacture parts of the required grain size in ultrasonic vibration-assisted WAAM fields.
电弧增材制造（WAAM）是一种具有竞争力的技术，可用于制造中型和大型金属部件。然而，由于增材制造零件中存在粗大的柱状晶粒，其所得机械性能会降低，这限制了WAAM工艺在工程领域的应用。通过引入超声振动可以实现晶粒细化并改善机械性能。在此，我们将超声振动应用于WAAM工艺，并研究了送丝速度、焊接速度和超声振幅对超声振动过程中焊缝成形和晶粒尺寸的影响。最后，建立了平均晶粒尺寸与送丝速度、焊接速度和超声振幅之间的回归模型。结果表明，由于热输入和熔覆量的差异，送丝速度、焊接速度和超声振幅对焊缝宽度和余高有显著影响。过大的超声振幅会导致焊缝在铺展过程中开裂。平均晶粒尺寸随送丝速度的增加和焊接速度的降低而增大。随着超声振幅的增加，平均晶粒尺寸呈现出先减小后增大的趋势。这将有助于在超声振动辅助的WAAM领域制造具有所需晶粒尺寸的零件。
