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金属学报  2025, Vol. 61 Issue (3): 397-419    DOI: 10.11900/0412.1961.2024.00314
  综述 本期目录 | 过刊浏览 |
镁合金电弧熔丝增材制造技术研究现状与展望
黄科(), 李新志, 方学伟, 卢秉恒
西安交通大学 机械工程学院 西安 710049
State-of-the-Art Progress and Outlook in Wire Arc Additive Manufacturing of Magnesium Alloys
HUANG Ke(), LI Xinzhi, FANG Xuewei, LU Bingheng
School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China
引用本文:

黄科, 李新志, 方学伟, 卢秉恒. 镁合金电弧熔丝增材制造技术研究现状与展望[J]. 金属学报, 2025, 61(3): 397-419.
Ke HUANG, Xinzhi LI, Xuewei FANG, Bingheng LU. State-of-the-Art Progress and Outlook in Wire Arc Additive Manufacturing of Magnesium Alloys[J]. Acta Metall Sin, 2025, 61(3): 397-419.

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摘要: 

电弧熔丝增材制造(WAAM)作为一种新兴的增材制造工艺，具有沉积效率高、成本低等优势，有望实现大型轻质镁合金复杂构件的一体化成形和规模化生产。然而，由于镁合金的低熔/沸点和高导热率等材料特性，导致WAAM构件中存在非均匀组织、冶金缺陷及应力变形，大幅降低了材料的可靠性和服役寿命，难以满足高端装备领域的使役要求，是亟需攻克的瓶颈问题。本文首先阐述了WAAM成形镁合金的工艺优势和技术挑战，然后从主流工艺、成形质量、冶金缺陷、组织特征和综合性能5个方面综述了近年来国内外关于镁合金WAAM成形方面的研究，并总结了基于液态熔池和固态层间的在线调控策略以及基于热处理和表面强化的整体后处理方案，为大型复杂镁合金构件的高质量成形提供相应的理论基础和指导策略。最后，从材料成分设计、组织缺陷在线调控、后处理形性协同调控以及构件性能评价等方面对WAAM镁合金的未来发展趋势与研究方向进行了总结与展望。
关键词 ： 电弧熔丝增材制造,  镁合金,  冶金缺陷,  微观组织,  综合性能,  调控策略    
Abstract：

Wire arc additive manufacturing (WAAM) is a promising additive manufacturing process known for its high deposition efficiency and cost effectiveness, making it well-suited for the large-scale production of complex, lightweight magnesium alloy components. Despite these advantages, magnesium alloys present challenges owing to their low melting and boiling points and high thermal conductivity, which result in nonuniform microstructures, metallurgical defects, and residual stresses in WAAM-manufactured components. These issues notably reduce the reliability and service life of the components, making it difficult to meet the demanding requirements of high-end equipment applications. It presents a critical challenge that must be addressed. This review outlines the advantages and technical challenges of WAAM, providing a comprehensive overview of recent domestic and international research in five key areas: process types, forming quality, metallurgical defects, microstructure characteristics, and overall performance. In addition, the present study summarizes in situ modulation strategies besed on the liquid melt pool and solid interlayer, as well as heat treatment and surface strengthening methods, providing a theoretical framework for improving the quality of large and complex magnesium alloy components. Finally, this review discusses future trends and research directions in WAAM for magnesium alloys, with a focus on composition design, in situ modulation, post-treatment processes, and performance evaluation.
Key words： wire-arc additive manufacturing    magnesium alloy    metallurgical defect    microstructure    comprehensive performance    modulation strategy
收稿日期: 2024-09-06     
ZTFLH:  TG669  
基金资助:国家自然科学基金项目(523B2049);国家自然科学基金项目(52275374);国家自然科学基金项目(52205414)
通讯作者: 黄 科，ke.huang@xjtu.edu.cn，主要从事金属增材制造(3D打印)、激光冲击强化等方面的研究
Corresponding author: HUANG Ke, professor, Tel: 13519183706, E-mail: ke.huang@xjtu.edu.cn
作者简介: 黄 科，男，1983年生，教授，博士
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https://www.ams.org.cn/CN/10.11900/0412.1961.2024.00314      或      https://www.ams.org.cn/CN/Y2025/V61/I3/397

图1  电弧熔丝增材制造(WAAM)成形设备[19]及大尺寸镁合金构件[3]
图2  WAAM成形镁合金的冶金缺陷、非均匀组织和力学性能[21~24,26]
图3  WAAM技术的原理图[27]
图4  打印参数对沉积单道形貌的影响[28]
图5  4种电弧模式下单道多层WE43镁合金薄墙件的形貌[19]
图6  WAAM制备GW63K镁合金薄壁件的缺陷分布状态[21]
图7  WAAM制备AZ31镁合金多道多层块体的缺陷分布状态[29]
图8  WAAM制备WE43镁合金墙状样品的氧化夹杂分布状态[37]
图9  AZ31镁合金在热轧态、钨极气体保护焊(GTAW)制备态和铸造态的晶粒尺寸和取向分布[35,38]
图10  GW系Mg-RE合金在铸造态、WAAM和激光定向能量沉积(LDED)制备下的析出相[26]
图11  WAAM制备不同镁合金系的晶粒尺寸和取向分布[24,26]
图12  本征热处理引起的WAAM制备WE43镁合金中的析出相演变[37]
AlloyDeposition processStateTensile direction

YS

MPa

UTS

MPa

EL

%

Ref.
Mg-3.12Al-0.84Zn-0.2MnGTAWADH10922320.3[35]
V9519113.8
AZ31GTAWADH5216211.8[42]
V13220117.2
Mg-2.98Al-0.93Zn-0.38MnGTAWADH9523921[29]
Mg-2.54Al-0.67Zn-0.44MnCMTADH8522628.3[31]
V12621117.2
Mg-2.54Al-0.67Zn-0.44MnCMTADH711527.5[30]
V13221110.6
Mg-2.5Al-0.82Zn-0.35MnCMTADH12022423.5[43]
V11321720.8
Mg-6.02Al-0.15Mn-0.88ZnGTAWAD-10526016[36]
Mg-7.6Al-0.25Mn-0.36Zn-0.15Ca-0.2YGTAWADH-28815[44]
V-22413
T6H-29216
V-28314
Mg-8.5Al-0.45Zn-0.03Mn-0.15Ca-0.2YGTAWADH14630815[32,45]
V11923712
AZ91DGTAWADH11324411.9[40]
V10824411.5
Mg-8.99Al-0.65Zn-0.26MnCMTADH-25017.5[33]
V-24516.3
Mg-4.26Gd-2.06Y-1.18Zn-0.36ZrCMTADH12322412.7[23]
V12122411.4
Mg-4.26Gd-2.06Y-1.18Zn-0.36ZrCMTT4H11723417.7[23]
V11422916.0
T6H15728817.1
V15728516.2
Mg-6.3Gd-2.6Y-0.4ZrGTAWADH1502328.3[21]
V1512378.9
T6V2183455.2
Mg-5.9Gd-2.8Y-0.7ZrCMTADH16226312.2[39]
V15925812.0
T4-15325717.9
T5H2273505.5
V2202385.7
T6-1993206.7
Mg-10.22Gd-2.14Y-0.43ZrCMTADH1492478.1[26]
V1512406.1
T4H12923814.6
V13224114.4
T6H2393714.0
V2433673.9
GWZ1031KGTAWADH1542718.7[25]
V1502473.3
T4H17028716.5
V16828512.7
T6H2153312.1
V2143372.7
Mg-4.08Y-2.11Nd-1.07Gd-0.54ZrGTAWADH1872575.2[37]
V1992718.1
Mg-3.82Y-2.46Nd-0.56ZrCMTADH15323310.4[41]
V14621110.3
表1  最优工艺参数下WAAM沉积态和热处理态镁合金的室温拉伸性能[21,23,25,26,29~33,35~37,39~45]
图13  采用WAAM工艺和传统工艺制备的AZ31镁合金腐蚀性能的比较[35,46](a) cast and CMT process[46] (b) hot roll and GTAW process[35]
图14  采用WAAM工艺和传统铸造工艺制备的AZ31镁合金阻尼性能的比较[38]
图15  其他金属材料在WAAM过程中的原位调控方案[49~51]
图16  超高频脉冲电弧的电流信号[52]
图17  超声振动辅助WAAM的设备[54]
图18  层间停留时间对热历史的影响[55]
图19  层间强化辅助WAAM的设备[58~60]
图20  WAAM制备的GW系镁合金在热处理过程中的微观组织演变示意图[26]
图21  WAAM制备的AZ31镁合金经过激光冲击处理后沿深度方向分布的梯度微观组织[48]
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