激光沉积薄壁结构热力演化的尺寸效应

doi:10.11900/0412.1961.2019.00317

金属学报

2020, Vol. 56

Issue (5): 745-752 DOI: 10.11900/0412.1961.2019.00317

本期目录 | 过刊浏览

激光沉积薄壁结构热力演化的尺寸效应

王霞¹^,², 王维¹^,²(

), 杨光², 王超², 任宇航²

1.沈阳工业大学机械工程学院沈阳 110870
2.沈阳航空航天大学机电工程学院沈阳 110136

Dimensional Effect on Thermo-Mechanical Evolution of Laser Depositing Thin-Walled Structure

WANG Xia¹^,², WANG Wei¹^,²(

), YANG Guang², WANG Chao², REN Yuhang²

1.School of Mechanical Engineering, Shenyang University of Technology, Shenyang 110870, China
2.School of Mechatronics Engineering, Shenyang Aerospace University, Shenyang 110136, China

引用本文:

王霞, 王维, 杨光, 王超, 任宇航. 激光沉积薄壁结构热力演化的尺寸效应[J]. 金属学报, 2020, 56(5): 745-752.
Xia WANG, Wei WANG, Guang YANG, Chao WANG, Yuhang REN. Dimensional Effect on Thermo-Mechanical Evolution of Laser Depositing Thin-Walled Structure[J]. Acta Metall Sin, 2020, 56(5): 745-752.

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摘要:

为研究激光沉积TC4单道薄壁结构热力演化的尺寸效应，采用有限元仿真和实验相结合的方法，分析了薄壁结构长度对温度、应力和基板变形的影响，并通过热电偶测温、基板残余变形验证了模型的可靠性。结果表明，熔池温度随层数循环递增，停光瞬间，试件最高温度急速下降，最低温度以抛物线形式持续上升。长度增加，对熔池极值温度影响不大，但会导致冷却曲线曲率变小，稳定降温速率加快，温度梯度变大。沉积过程中首层应力最大，随层数增加，应力递减，冷却过程中又逐步回升。长度增加，导致首层应力增大，沉积过程中低应力区和冷却过程中高应力区均围绕在薄壁结构附近，其范围扩大，但数值未见增大。沉积过程中基板会产生方向和大小不断变化的纵向翘曲变形，冷却后固定为朝向光源。长度增加，翘曲会更加明显。冷却过程中，基板变形比温度和应力更早达到平衡。

关键词 ：激光沉积, 热力演化, 尺寸效应, 有限元仿真, 薄壁结构

Abstract：

To accurately predict and effectively control temperatures, stresses and distortions are key problems existing in laser deposition manufacturing technology. The mechanism of thermo-mechanical evolution during the metal depositing process is not yet clear. In order to study the dimensional effect on thermo-mechanical evolution when TC4 single-pass and thin-walled structures are manufactured by laser deposition, finite element simulations and experiments are combined to explore the influence of the structures' length on temperature, stress and distortion of the substrates. The model reliability is validated by thermocouple temperatures and the residual deformations of substrates. The results show that the temperatures of molten pools increase periodically according to the depositing layers. As soon as the laser is terminated, the maximum temperatures of builds decline at high speed, but the minimum temperatures continue to rise in the form of parabola. When the lengths of thin-walled structures increase, the thermal extremes of molten pools are not affected, but the curvatures of cooling curves diminish, the steady cooling rates accelerate, meanwhile the temperature gradients increase. The initial stresses when depositing the first layer are maximum during manufacturing, the stresses decline progressively with the increasing layer numbers, but recover during cooling. While the lengths expand, stresses of the first layer increase. At the same time both low stress regions during depositing and high stress areas during cooling are enlarged which are around the depositing structures, but the lengths of thin-walled structures appear to have a minimal impact on the stress magnitudes. During deposition, the out-of-plane distortions of the substrates oscillate up and down, after cooling the directions of deformations are fixed towards the light source. The out-of-plane distortions are more obvious as the lengths increase. During cooling the substrates' deformations reach equilibrium earlier than temperatures and stresses.

Key words： laser deposition thermo-mechanical evolution dimensional effect finite element simulation thin-walled structure

收稿日期: 2019-09-25

ZTFLH:

V261.8

基金资助:国家自然科学基金项目(51975387);国家重点研发计划项目(2016YFB1100504);沈阳航空航天大学航空制造工艺数字化国防重点学科实验室开放基金项目(SHSYS2015006)

作者简介: 王霞，女，1975年生，讲师，博士生

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https://www.ams.org.cn/CN/10.11900/0412.1961.2019.00317 或 https://www.ams.org.cn/CN/Y2020/V56/I5/745

图1 试件尺寸和热电偶测温点、位移测量点位置示意图

图2 有限元模型和沉积方式

图3 T1~T5热电偶测量和模拟温度曲线以及薄壁长度不同时试件最高和最低温度曲线

图4 最高温度曲线中沉积段峰值和谷值温度以及最低温度曲线中峰值和终值温度

图5 薄壁长度为20、30和40 mm时第1层结束、第6层结束和冷却100 s时的von Mises 应力分布云图

图6 D1~D3的垂直位移历史曲线

图7 薄壁长度为30 mm时0.25、3.75和15.875 s 变形分布云图

图8 薄壁长度为20、30和40 mm时模拟和测量的残余变形

图9 薄壁长度为40 mm时温度、应力和基板变形历史曲线

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