目的 针对316L不锈钢与铜在滚动摩擦沉积增材制造中因热物理性能失配而导致的界面热输入不足与材料流动协调性差等问题,引入电阻辅助加热工艺,系统探究其对热-力-流行为的调控机制,以提升异种合金固相增材制造的成形质量与界面性能。方法 基于Abaqus软件建立耦合欧拉-拉格朗日（CEL）法的三维热-力-流多场耦合数值模型,模拟316L-Cu异种合金AFRD过程,并通过初步实验验证模型可靠性。采用Johnson-Cook本构方程描述材料高温流变行为,系统研究辅热温度（25~700 ℃）、增材速度（180~300 mm/min）及工具头转速（750~1 000 r/min）等多组工艺参数。通过示踪粒子法追踪材料迁移路径,并结合等效塑性应变场分析,深入揭示辅热对温度分布、塑性区扩展、材料流动模式及界面混合行为的影响规律。结果 电阻辅助加热显著提升了界面热积累与材料流动性。在辅热温度600 ℃、增材速度240 mm/min、旋转速度850 r/min的工况下,界面峰值温度由无辅热时的722 ℃显著提升至841 ℃,高温停留时间由1.2 s延长至2.5 s。示踪粒子分析结果表明,材料在增材方向的x向最大迁移距离从10.95 mm增加至11.46 mm,在厚度方向的z向最大迁移距离从2.31 mm增加至2.63 mm,材料流动能力全面提升,形成了更宽、更均匀的界面混合区。等效塑性应变分析进一步揭示,辅热诱导了应变局域化现象,使高应变区由宽泛分布转变为集中于狭窄剪切带,最大等效塑性应变值从无辅热时的58.8降低为55.2,实现了由宽而浅的强迫变形向窄而深的高效剪切流动的模式转变。初步实验验证表明,模拟结果在宏观形貌与关键尺寸上与实验结果吻合良好。结论 电阻辅助加热通过提升热输入、促进材料软化并诱导应变局域化,有效协调了316L-Cu异种合金在AFRD过程中的流动行为,解决了因热物理性能失配而导致的界面结合难题。研究阐明了热输入-材料软化-应变局域化-协调流动的作用链条,表明界面结合质量并非仅取决于高的平均塑性应变,而在于通过热-力协同实现变形能的优化分布与高效利用。本研究为异种合金高性能固相增材制造提供了重要的理论依据与工艺优化方向。
Abstract
To solve the problems of insufficient interfacial heat input and poor material flow coordination caused by mismatch of thermophysical properties between 316L stainless steel and copper in rolling friction deposition additive manufacturing, the work aims to introduce resistance-assisted heating process to systematically explore its regulation mechanism on thermo-mechanical-flow behavior, so as to improve the forming quality and interfacial properties of dissimilar alloys fabricated by solid phase additive manufacturing. Based on Abaqus software, a three-dimensional thermal-mechanical-flow multi-field coupling numerical model coupled with Euler-Lagrange (CEL) method was established to simulate the AFRD process of 316L-Cu dissimilar alloy, and the reliability of the model was verified by preliminary experiments. The Johnson-Cook constitutive equation was used to describe the high temperature rheological behavior of the material. The process parameters such as auxiliary heating temperature (25-700 ℃), additive speed (180-300 mm/min) and tool head rotation speed (750-1 000 r/min) were systematically studied. The effect of auxiliary heat on temperature distribution, plastic zone expansion, material flow mode and interface mixing behavior was deeply revealed by tracing the material migration path with tracer particle method and combining with the analysis of equivalent plastic strain field. The resistance-assisted heating significantly improved the interfacial heat accumulation and material fluidity. Under the conditions of auxiliary heat temperature of 600 ℃, additive speed of 240 mm/min and rotation speed of 850 r/min, the peak temperature of the interface significantly increased from 722 ℃ under no auxiliary heat to 841 ℃, and the high temperature residence time was prolonged from 1.2 s to 2.5 s. The tracer particle analysis showed that the maximum migration distance of the material in the x direction of the additive direction increased from 10.95 mm to 11.46 mm, and the maximum migration distance in the z direction of the thickness direction increased from 2.31 mm to 2.63 mm. The flow ability of the material was improved in an all-round way, forming a wider and more uniform interface mixing zone. The equivalent plastic strain analysis further revealed that the auxiliary heat induced the strain localization phenomenon, which changed the high strain zone from a wide distribution to a concentrated narrow shear band. The maximum equivalent plastic strain value was reduced from 58.8 to 55.2 when there was no auxiliary heat, and the mode transitioned from wide and shallow forced deformation to narrow and deep efficient shear flow. Preliminary experimental verification showed that the simulation results were in good agreement with the experimental results in terms of macroscopic morphology and key dimensions. The resistance-assisted heating effectively coordinates the flow behavior of 316L-Cu dissimilar alloy in AFRD process by increasing heat input, promoting material softening and inducing strain localization, and solves the interface bonding problem caused by mismatch of thermophysical properties. The work clarifies the action chain of heat input-material softening-strain localization-coordinated flow, indicating that the interface bonding quality depends on not only the high average plastic strain, but also the optimal distribution and efficient utilization of deformation energy through thermo-mechanical synergy, providing an important theoretical basis and process optimization direction for high-performance solid phase additive manufacturing of dissimilar alloys.
关键词
电阻辅助加热 /
异种合金 /
滚动摩擦沉积增材制造 /
热-力-流行为 /
应变局域化
Key words
resistance-assisted heating /
dissimilar alloys /
rolling friction deposition additive manufacturing /
thermo-mechanical-flow behavior /
strain localization
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