目的 研究316L/IN625功能梯度材料双丝等离子电弧制造工艺参数对单道沉积层外观成形的影响,为揭示功能梯度材料在增材制造过程中“成分-工艺-成形”的内在关联提供试验数据支撑,同时为后续多道多层沉积及成形质量调控奠定理论与技术基础。方法 使用1.2 mm的316L焊丝和IN625焊丝在304L不锈钢基板上进行单道沉积层试验。设计包含5个成分梯度（316L、75% 316L、50% 316L、25% 316L、IN625,质量分数）的梯度功能材料共80组试验,以焊接电流（Ic）、送丝速度（Sf）和焊接速度（Ts）3个参数为输入,以沉积层熔宽（W）、熔高（H）、润湿角（θ）和稀释率（D）为输出,建立二次多项式回归模型拟合不同成分梯度的单道沉积层成形试验数据。结果 80组试验样品堆积制备过程都比较稳定,表面成形良好,飞溅较少,单道沉积层外观无裂纹和塌陷等明显缺陷。建立的二次回归模型拟合值与实际值之间相差很小,模型拟合精度较好。通过模型可以发现,梯度组成成分、送丝速度、焊接速度以及焊接电流对沉积层成形都有显著影响。送丝速度主要影响沉积层熔宽、熔高以及润湿角;焊接速度对沉积层熔高和熔宽具有显著影响;焊接电流则对所有输出参数都具有明显影响。分析不同成分区域二次多项式回归模型与各项系数可以看出,成分梯度不同造成材料特性不同,对输出参数也存在显著性影响。结论 二次回归模型能够精确拟合双丝等离子电弧增材制造系统不同工艺参数下单道沉积层外观成形数据,对工艺参数进一步优化有重要参考价值。
Abstract
The work aims to study the effect of the dual-wire plasma arc additive manufacturing (DW-PAAM) process on the appearance and forming quality of single-pass depositions for 316L/IN625 functional gradient materials (FGMs), provide experimental data for revealing the relationship of "composition-process-formation" during the additive manufacturing of FGMs, and lay a theoretical and technical foundation for subsequent multi-layer deposition as well as the regulation of forming quality. Single-pass deposition experiments were conducted on 304L stainless steel substrates using 1.2 mm-diameter 316L and IN625 welding wires. A total of 80 sets of experiments were designed for FGMs with five composition gradients (316L, 75wt% 316L-25wt% IN625, 50wt% 316L-50wt% IN625, 25wt% 316L-75wt% IN625, IN625). Taking welding current (Ic), wire feed speed (Sf), and welding speed (Ts) as input parameters, and weld width (W), weld height (H), contact angle (θ), and dilution rate (D) of the deposition layer as output parameters, a quadratic polynomial regression model was established to fit the single-pass deposition forming of different composition gradients. Results showed that all 80 sets of test samples exhibited stable deposition processes, good surface forming, minimal spatter, and no obvious defects such as cracks or collapse were observed on the surface of the single-pass deposition layers. The fitted values of the established quadratic regression model showed a small deviation from the actual values, indicating high fitting accuracy. The model revealed that the gradient composition, wire feed speed, welding speed, and welding current all had significant effects on the deposition forming. The wire feed speed mainly affected the weld width, weld height, and contact angle; the welding speed had a significant effect on the weld height and width; and the welding current exerted an obvious effect on all output parameters. Analysis of the quadratic polynomial regression models and their coefficients in different composition regions indicated that the differences in material properties caused by different composition gradients also had significant effects on the output parameters. In conclusion, the quadratic regression model can accurately fit the appearance of single-pass deposition layers under different process parameters of the dual-wire plasma arc additive manufacturing system, and provides important reference value for the further optimization of process parameters.
关键词
功能梯度材料 /
等离子电弧 /
多项式回归模型 /
增材制造 /
316L/IN625
Key words
functional gradient materials (FGMs) /
plasma arc /
polynomial regression model /
additive manufacturing /
316L/IN625
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基金
国家自然科学基金（51875213）; 广东省普通高校重点领域专项（2024ZDZX3045）; 广东省学习型社会建设质量提升工程项目（JXJYGC2024C148）; 广东省普通高校创新团队项目（2024KCXTD073）
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