Study on Heat Generation Mechanism and Melting Behavior of Droplet Transition in Resistive Heating Metal Wires

doi:10.11900/0412.1961.2018.00035

Acta Metall Sin

2018, Vol. 54

Issue (9): 1297-1310 DOI: 10.11900/0412.1961.2018.00035

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Study on Heat Generation Mechanism and Melting Behavior of Droplet Transition in Resistive Heating Metal Wires

Shujun CHEN¹, Chengwei YUAN¹, Fan JIANG¹(

), Zhihong YAN¹, Pengtian ZHANG²

1 Engineering Research Center of Advanced Manufacturing Technology for Automotive Components, Ministry of Education, College of Mechanical Engineering and Applied Electronics Technology, Beijing University of Technology, Beijing 100124, China
2 Beijing Satellite Manufacturing Co., Ltd., Beijing 100094, China

Cite this article:

Shujun CHEN, Chengwei YUAN, Fan JIANG, Zhihong YAN, Pengtian ZHANG. Study on Heat Generation Mechanism and Melting Behavior of Droplet Transition in Resistive Heating Metal Wires. Acta Metall Sin, 2018, 54(9): 1297-1310.

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Abstract

With the development of space technology, the ability of manufacturing in space is a necessary guarantee for a long-term space mission. To achieve the repair and maintenance of spacecraft structure in space, a metal additive manufacturing method named resistance heating metal wire additive manufacturing process has been proposed in this work. During the experiments, the wire and the base plate are short-circuited, the current output from the programmable power source flows through the wire and the base plate to generate resistance heat, and then the wire begins to melt and transfer to the base plate. A real-time synchronization system has been used to record the current, voltage and image of metal wire synchronously, to study the melting process of metal wire by resistance heating. The direct current and pulse current with different amplitudes which were supplied by programmable power source have been used to study the effect of the current style and value on the melting process and transition behavior of metal wire. The change characteristic of the resistance in the wire and base plate has been analyzed during wire melting, to study the relationship between the current resistance and the wire state. The effect of gravity on the wire melting process has been studied by the wire transfer experiments at different space locations. The results show that when the metal wire was heated by the constant current, the total heat of metal melt could be controlled by controlling the current value, but it was difficult to precisely control the heating speed and the heat input. When using pulse current heating, both the heating speed and the heat input could be precisely controlled by pulse frequency and pick value. In the melt transfer stage, the constant current provides a fixed force on the molten wire, but the pulse current makes the molten wire swing by the intermittent force. The real-time resistance of metal wire during heating could be used to reflect the melting state of wire in both current styles. On the ground environment, the surface tension and electromagnetic contraction force make the melting wire against the gravity and transfer to the base plate, which illustrated the feasibility of using this process in space environment.

Key words: programmable power supply resistance heating melt transition dynamic resistance

Received: 19 January 2018

ZTFLH:

TG441.2

Fund: Supported by National Natural Science Foundation of China (No.51475009)

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	Shujun CHEN
	Chengwei YUAN
	Fan JIANG
	Zhihong YAN
	Pengtian ZHANG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2018.00035 OR https://www.ams.org.cn/EN/Y2018/V54/I9/1297

Fig.1 Schematic of the resistance heating wire experiment

Fig.2 The principle of the resistance heating wire
(a) there are sharp edges and burrs between the wire and the substrate
(b) the contact area between the wire and the substrate increases
(c) the wire melts and forms a necking
(d) droplet transition

Fig.3 The experimental device of the resistance heating wire

Table 1 Resistive heating wire material process parameters

Fig.4 130 A constant current resistance heating metal wire melting and transition process
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.5 The curve of 130 A constant current with time
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.6 155 A constant current resistance heating metal wire melting and transition process
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.7 The curve of 155 A constant current and time
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.8 180 A constant current resistance heating metal wire melting and transition process
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.9 The curve of 180 A constant current and time
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.10 216 A-0 A pulse current resistance heating wire melting and transition metal process
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.11 The curve of 216 A-0 A pulse current and time
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.12 258 A-0 A pulse current resistance heating wire melting and transition metal process
(a) eliminate burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.13 The curve of 258 A-0 A pulse current and time
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.14 300 A-0 A pulse current resistance heating wire melting and transition metal process
( (a) eliminating burrs and sharp phase
( (b) metal wire melting phase
( (c) droplet transition phase

Fig.15 The curve of 308 A-0 A pulse current and time
(a) eliminating burrs and sharp phase
(b) metal wire melting phase
(c) droplet transition phase

Fig.16 Effect of substrate electrode position on metal melt (F₁ and F₂ are electromagnetic contraction forces, φ⁺ is positive wire,φ^-is negative wire)
(a) the substrate electrode position is on the right and the melt is left-biased
(b) the substrate electrode position is on the left and the melt is right-biased

Fig.17 Schematics of the droplet force when the wire is perpendicular (a1~a4) and parallel (b1~b4) to the ground (G—gravity; F_σ, F_σ₁ and F_σ₂—surface tensions; F_m, F_m1 and F_m2—electromagnetic contraction forces)

Fig.18 Constant current melt offset
(a) left indent size
(b) right indent size
(c) necking size

Fig.19 Constant current melt transition with the constant currents of 130 A (a, b), 155 A (c, d) and 180 A (e, f) before (a, c, e) and after (b, d, f) metal melt fracture

Fig.20 Pulse current melt offset
(a) left indent size
(b) right indent size
(c) neck size

Fig.21 Pulse current melt transition with the pulse currents of 216 A-0 A (a, b), 258 A-0 A (c, d) and 300 A-0 A (e, f) before (a, c, e) and after (b, d, f) metal melt fracture

Fig.22 Constant current dynamic resistance change trend
(a) deburring and sharp edge stage
(b) solid phase heating stage
(c) metal wire melting stage
(d) metal melt transition stage

Fig.23 Pulse current dynamic resistance change trend
(a) deburring and sharp edge stage
(b) solid phase heating stage
(c) metal wire melting stage
(d) metal melt transition stage

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