Microstructure and mechanical properties of aluminium alloy thin-wall parts in wire arc additive manufacturing hybrid interlayer high-speed friction
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摘要: 为提高丝材电弧增材制造(wire arc additive manufacturing，WAAM)构件性能，提出了一种电弧增材制造复合层间高速摩擦(wire arc additive manufacturing hybrid interlayer high speed friction，WAAM-HSF)的方法. 采用直径1.2 mm的4047铝硅焊丝，使用WAAM-HSF方法进行薄壁构件制造，对比研究了WAAM和WAAM-HSF对铝合金薄壁构件的微观结构和力学特性的影响. 结果表明，WAAM和WAAM-HSF构件的微观结构中存在着大量的柱状树枝晶. 与WAAM相比，WAAM-HSF构件的微观结构明显细化. 同时，不同工艺的晶粒分布趋势一致，即晶粒直径在两个薄壁中从顶部到底部逐渐减小. 在相同区域，WAAM构件的晶粒尺寸大于WAAM-HSF构件. 通过破坏外延结晶的生长，达到细化晶粒的目的. 与WAAM相比，WAAM-HSF构件的平均断后伸长率减小了5%；但WAAM-HSF构件的平均显微硬度和平均抗拉强度则分别提高了9.96 HV和17 MPa.Abstract: A wire arc additive manufacturing hybrid interlayer high speed friction (WAAM-HSF) approach is proposed to improve the performance of wire arc additive manufacturing (WAAM) components. The effect of WAAM and WAAM-HSF on the microstructure and mechanical properties of thin-walled aluminium alloy components was investigated using 1.2 mm diameter 4047 Al-Si wire using the WAAM-HSF method. The results show that the microstructures of the WAAM and WAAM-HSF components contain a large number of columnar dendrites. Compared to WAAM, the microstructure of WAAM-HSF components is significantly finer. At the same time, the grain distribution tends to be the same for the different processes, i.e. the grain diameter decreases from the top to the bottom in both thin walls. Grain refinement is achieved by disrupting the growth of epitaxial crystals. Compared to WAAM, the average elongation at break of WAAM-HSF components is reduced by 5%, but the average microhardness and average tensile strength of WAAM-HSF components are increased by 9.96 HV and 17 MPa, respectively.
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图 1 WAAM-HSF试验系统示意图
Figure 1. Schematic representation of the WAAM-HSF experimental system
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图 2 试样切取位置和拉伸试样尺寸图
Figure 2. Specimen cutting locations and tensile specimen dimensions. (a) cutting position of the specimen; (b) size of the tensile specimen
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图 3 薄壁构件不同区域的微观组织
Figure 3. Microstructure of different areas of thin wall member. (a) bottom of WAAM component; (b) middle of WAAM component; (c) top of WAAM component; (d) bottom of WAAM-HSF component; (e) middle of WAAM-HSF component; (f) top of WAAM-HSF component
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图 4 WAAM和WAAM-HSF构件的不同位置EDS扫描图像
Figure 4. EDS scan images of WAAM and WAAM-HSF at different positions. (a) top of WAAM; (b) middle of WAAM; (c) bottom of WAAM; (d) top of WAAM-HSF; (e) middle of WAAM-HSF; (f) bottom of WAAM-HSF
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图 7 WAAM试样的断口形貌
Figure 7. Fracture morphology of WAAM sample. (a) fracture morphology; (b) amplification of area B
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图 8 WAAM-HSF试样的断口形貌
Figure 8. Fracture morphology of WAAM-HSF sample. (a) fracture morphology; (b) amplification of area D
表 1 4047焊丝和2A12基板化学成分(质量分数，%)
Table 1 Chemical compositions of 4047 wire and 2A12 substrate
材料 Si Fe Cu Mg Mn Ni Zn Al 4047 11 ~ 13 ≤ 0.6 ≤ 0.3 ≤ 0.1 ≤ 0.15 ≤ 0.05 ≤ 0.20 余量 2A12 ≤ 0.50 0 ~ 0.5 3.8 ~ 4.9 1.2 ~ 1.8 0.30 ~ 0.9 ≤ 0.10 ≤ 0.30 余量 
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表 2 焊接工艺参数
Table 2 Welding process parameters
保护气体流量Q/(L·min−1) 焊丝伸出长度l/mm 送丝速度 v/(m·min−1) 沉积速度
vd/(mm·s−1)弧长L/mm 15 18 5 8.5 5
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