Duan Xiaoming, Cui Ruirui, Yang Haiou, Yang Xiaodong
Department of Mechanical Engineering and Automation, Harbin Institute of Technology, Harbin 150001, China.
Department of Materials Science and Engineering, Northwestern Polytechnical University, Xi'an 710072, China.
Materials (Basel). 2023 Jun 24;16(13):4561. doi: 10.3390/ma16134561.
In this study, a novel hybrid additive and subtractive manufacturing method using pulsed arc plasma (PAP-HASM) was developed to better integrate additive and subtractive processes. The PAP-HASM process is based on the flexible application of pulsed arc plasma. In this PAP-HASM method, wire arc additive manufacturing using pulsed arc plasma (PAP-WAAM) and dry electrical discharge machining (EDM) milling were used as additive and subtractive techniques, respectively; both are thermal machining processes based on pulsed arc plasma, and both are dry machining techniques requiring no working fluids. The PAP-HASM can be easily realized by only changing the pulsed power supply and tool electrodes. A key technological challenge is that the recast layer on the part surface after dry EDM milling may have a detrimental effect on the component fabricated by PAP-HASM. Here, the hybrid manufacturing method developed in this study was validated with commonly used 316L stainless steel. Preliminary experimental results showed that the PAP-HASM specimens exhibited excellent tensile properties, with an ultimate tensile strength of 539 ± 8 MPa and elongation of 46 ± 4%, which were comparable to the PAP-WAAM specimens. The recast layer on the surface after dry EDM milling has no significant detrimental effect on the mechanical properties of the parts fabricated by PAP-HASM. In addition, compared with components fabricated by PAP-WAAM, those fabricated by PAP-HASM showed significantly better surface roughness.
在本研究中，开发了一种使用脉冲电弧等离子体的新型混合增材与减材制造方法（PAP-HASM），以更好地整合增材和减材工艺。PAP-HASM工艺基于脉冲电弧等离子体的灵活应用。在这种PAP-HASM方法中，使用脉冲电弧等离子体的电弧增材制造（PAP-WAAM）和干式电火花加工（EDM）铣削分别用作增材和减材技术；两者都是基于脉冲电弧等离子体的热加工工艺，并且都是无需工作液的干式加工技术。通过仅改变脉冲电源和工具电极，就可以轻松实现PAP-HASM。一个关键的技术挑战是，干式EDM铣削后零件表面的重铸层可能会对PAP-HASM制造的部件产生不利影响。在此，本研究中开发的混合制造方法用常用的316L不锈钢进行了验证。初步实验结果表明，PAP-HASM试样具有优异的拉伸性能，极限抗拉强度为539±8MPa，伸长率为46±4%，与PAP-WAAM试样相当。干式EDM铣削后表面的重铸层对PAP-HASM制造的零件的机械性能没有明显的不利影响。此外，与PAP-WAAM制造的部件相比，PAP-HASM制造的部件表面粗糙度明显更好。
