目的 针对在大型悬垂构件原位再制造过程中直接应用电弧增材制造成形时,易出现流淌、驼峰以及强度不足等问题,研究无支撑电弧增材制造的成形工艺。方法 采用电弧冷金属过渡技术在竖直基板上增材制造Cr13Ni5Mo不锈钢,建立电弧增材制造工艺参数与成形形貌的数学模型,研究送丝速度、焊接速度及焊枪偏转角度对单道焊道截面尺寸的影响规律,采用二次回归拟合方程选定的最佳工艺参数成形单道多层试样,并对试样进行力学性能检测,按照规范完成制样,使用万能拉伸试验机测试无支撑电弧增材制造Cr13Ni5Mo不锈钢的拉伸力学性能。结果 数学模型预测结果与实际结果较为符合,根据方差分析求得焊宽、余高及余高偏移量方程模型的F值分别为18.64、9.78、8.99,由显著性水平α=0.01查找F_α表,再根据fR、fQ,得出F_0.99 (fR, fQ)=4.94,显著水平均超过0.99。送丝速度对焊宽影响最为显著,焊接速度对余高影响最大,焊枪偏转角度对余高偏移量影响最大。拉伸力学性能测试结果表明,横向平均抗拉强度为1 017.3 MPa,延伸率为13.7%,纵向平均抗拉强度为1 067.5 MPa,延伸率为15.6%。结论 基于Cr13Ni5Mo不锈钢的无支撑电弧增材制造成形工艺不仅能够控制流淌、驼峰等缺陷,还能实现优良的力学性能,为后续大型构件的原位增材制造提供了参考。
Abstract
For arc additive manufacturing based on large non-overturnable components, directly applying conventional arc additive forming processes is prone to issues such as flow, humping, and insufficient strength. Therefore, the work aims to study the forming process of support-free arc additive manufacturing. The arc cold metal transfer technology was used to additively manufacture Cr13Ni5Mo stainless steel on a vertical substrate. A mathematical model of arc additive manufacturing process parameters and forming morphology was established. The impact of wire feed speed, welding speed, and torch deflection angle on the cross-sectional dimensions of a single weld bead was investigated. Based on the quadratic regression fitting equation, the optimal process parameters were selected to form a single-layer multi-bead specimen, and the mechanical properties of the specimen were tested. The specimen was prepared completely according to specifications, and the tensile mechanical properties of the support-free arc additive manufactured Cr13Ni5Mo stainless steel were tested with a universal tensile testing machine. The mathematical model prediction was consistent with the actual results. Based on the ANOVA results, the F-values for the regression models of weld width, weld reinforcement height, and reinforcement deviation were 18.64, 9.78, and 8.99, respectively. Using a significance level of α=0.01 and referencing the F-distribution table with degrees of freedom fR, fQ, the critical value F_0.99 (fR, fQ)=4.94 was determined. Since all computed F-values exceeded this critical value, the statistical significance level for each model surpassed 99%. The wire feed speed had the most significant impact on weld width, the welding speed had a significant impact on reinforcement, and the torch deflection angle had the greatest impact on the amount of reinforcement offset. The tensile mechanical property test results showed that the average transverse tensile strength was 1 017.3 MPa, with an elongation of 13.7%, and the average longitudinal tensile strength was 1 067.5 MPa, with an elongation of 15.6%. The support-free arc additive manufacturing forming process based on Cr13Ni5Mo stainless steel in this work not only controls defects such as flow and humping but also contributes to excellent mechanical properties, providing a reference for subsequent in-situ additive manufacturing of large components.
关键词
电弧增材制造 /
Cr13Ni5Mo不锈钢 /
无支撑成形 /
成形形貌 /
力学性能
Key words
arc additive manufacturing /
Cr13Ni5Mo stainless steel /
support-free forming /
deposit morphology /
mechanical properties
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基金
中国长江电力股份有限公司科研项目（Z232402013）
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