Influence of Wire Feeding Mode on Formation of Single-pass Multilayer Inclined Parts in Laser Wire Additive Manufacturing
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摘要:
为了研究送丝方式对激光熔丝增材制造倾斜零件成形的影响，在前置送丝、后置送丝和侧置送丝方式下进行单道多层倾斜零件的激光熔丝沉积实验，对比分析了倾斜零件的宏观形貌、截面形貌、成形尺寸和各沉积层轮廓拟合圆心轨迹的变化. 结果表明：旁轴送丝的送丝方式对激光熔丝单道多层倾斜零件的宏观形貌、各沉积层的平均层高、平均壁厚和平均倾斜角度均有影响. 后置送丝制造倾斜零件的层高波动值和壁厚波动值最小，倾斜角误差也较小，成形精度较好；侧置送丝制造倾斜零件的层高波动值、壁厚波动值和倾斜角误差最大，成形精度较差. 后置送丝时焊丝可稳定地送入到熔池中后部，各沉积层的实际成形位置稳定，制造的各倾斜零件的成形精度相对较好.
Abstract:In order to study the influence of wire feeding mode on the formation of inclined parts in laser wire additive manufacturing, the laser wire deposition experiments of single-pass multilayer inclined parts were carried out under the modes of front wire feeding, rear wire feeding and side wire feeding. The changes of macroscopic morphology, cross-sectional morphology, forming size and the fitted center trajectory of each deposited layer contour were compared and analyzed. The results show that the paraxial wire feeding mode has an influence on the macroscopic morphology, average height, average wall thickness and average inclined angle of the single-pass multilayer inclined part. The height fluctuation value and wall thickness fluctuation value of the inclined part manufactured by rear wire feeding are the smallest, and the inclined angle error is also small, so the forming accuracy is better. The height fluctuation value, wall thickness fluctuation value and inclined angle error of inclined parts manufactured by side wire feeding are the largest, and the forming accuracy is poor. The welding wire can be stably fed into the middle and rear part of the molten pool under rear wire feeding mode, the actual forming position of each deposited layer is stable, and the forming accuracy of each inclined part is relatively better.
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图 1 不同送丝方式时焊丝、激光束和扫描方向的相对位置
(a)前置送丝(b)后置送丝(c)侧置送丝
Figure 1. Relative position of welding wire, laser beam and scanning direction in different wire feeding modes. (a) front wire feeding; (b) rear wire feeding; (c) side wire feeding
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图 2 获得包含每层顶部轮廓曲线的截面形貌图的方法
(a)提取每层相同位置截面处的轮廓曲线 (b) 在截面形貌图中添加每层的顶部轮廓曲线
Figure 2. Method of obtaining cross-sectional topography containing top contour curve of each layer. (a) extracting section contour curve of each layer at the same position; (b) adding top contour curve of each layer to section topography
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图 3 不同送丝方式下倾斜零件的三维扫描图
Figure 3. Three-dimensional scanning diagram of inclined parts under different wire feeding modes. (a) sample 1 of front wire feeding; (b) sample 2 of rear wire feeding; (c) sample 2 of side wire feeding
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图 4 不同送丝方式下各试样包含每层顶部轮廓曲线的截面形貌图
Figure 4. Cross-sectional topography of each sample containing top contour curve of each layer under different wire feeding modes.
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图 5 倾斜零件倾斜角度和壁厚的测量原理
Figure 5. Measurement principle of inclination angle and wall thickness of inclined parts
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图 6 单道多层倾斜零件的理想模型与试样中沉积层轮廓拟合圆心的变化
(a)理想模型(b)试样中各沉积层轮廓拟合圆心的变化
Figure 6. Ideal model of a single-pass multilayer inclined part and change of the fitted center of deposited layer contour in the sample. (a) ideal model; (b) change of the fitted center of each deposited layer contour in the sample
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图 7 前置送丝和后置送丝时焊丝熔入熔池的图像
(a)前置送丝(b)后置送丝
Figure 7. Images of welding wire melting into molten pool under front and rear wire feeding modes. (a) front wire feeding; (b) rear wire feeding
表 1 不同送丝方式下倾斜零件的成形尺寸
Table 1 Forming dimensions of inclined parts under different wire feeding modes
送丝方式 平均层高
ha/mm层高波动值
σh /mm平均壁厚
δa/mm壁厚波动值
σδ /mm平均倾斜角度
θa/°倾斜角误差
△θ/°前置 0.459 0.084 2.506 0.156 56.49 0.18 后置 0.467 0.071 2.424 0.125 56.65 0.34 侧置 0.429 0.14 2.511 0.196 54.88 -1.43 
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表 2 不同送丝方式下各试样沉积层轮廓拟合圆心的直线拟合度R2
Table 2 Linear fitting degree R2 of the fitted center of deposited layer contour in each sample under different wire feeding modes.
送丝方式 沉积层轮廓拟合圆心的直线拟合度R2 试样1 R21 试样2 R22 试样3 R23 平均值R2a 前置 0.9864 0.9839 0.9569 0.9757 后置 0.9886 0.9947 0.9968 0.9934 侧置 0.9156 0.9849 0.9326 0.9444
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