电弧增材制造传热传质数值模拟技术综述  

An Overview of Numerical Simulation of Heat and Mass Transfer in Wire Arc Additive Manufacturing

作　　者：郭鑫鑫 魏正英[1] 张永恒 张帅锋 GUO Xinxin;WEI Zhengying;ZHANG Yongheng;ZHANG Shuaifeng(State Key Laboratory for Manufacturing Systems Engineering,Xi'an Jiaotong University,Xi'an 710049,China;Luoyang Ship Material Research Institute,Luoyang 471039,Henan,China)

机构地区：[1]西安交通大学精密微纳制造技术全国重点实验室,西安710049 [2]中国船舶集团有限公司第七二五研究所,河南洛阳471039

出　　处：《材料导报》2024年第9期186-192,共7页Materials Reports

基　　金：应用创新项目;国家自然科学基金(52275376)。

摘　　要：电弧增材制造过程涉及丝材的送入和熔化,熔融金属向熔池的过渡,熔池中液态金属的对流、凝固和成形。缺陷的形成与电弧增材制造过程中发生的复杂多物理场现象密切相关。因此,需要借助高保真数值模拟技术来深入理解这些物理现象,并将其作为优化工艺条件、制造高质量产品的理论依据。本文综述了电弧增材制造传热传质数值模拟涉及的关键技术,并对未来研究方向进行了展望:首先,介绍了几种典型的热源模型,鉴于电弧增材制造过程中熔池的形成与演变是多种驱动力共同作用的结果,分析了浮力、电磁力、表面张力、电弧压力、电弧剪应力模型对流体流动和熔池表面变形的影响;然后,总结了三种金属过渡模型,包括速度入口填充液态金属、指定位置添加球状质量源项以及直接建立固态金属焊丝;最后,介绍了常用的气液界面跟踪方法。The wire arc additive manufacturing(WAAM)process involves the feeding and melting of wire,the transition of metal to a molten pool,the convection of liquid metal within the pool,and solidification.Defects may arise due to the complex,multi-physics nature of the process.Therefore,it is necessary to comprehend these physical phenomena through high-fidelity numerical simulations to establish a theoretical foundation for optimizing process conditions and producing high-quality products.This paper provides a comprehensive review of the key technologies involved in the numerical modeling of heat and mass transfer within WAAM and offers an outlook on potential future research directions.First,an overview of various heat source models is presented.Given that the formation and evolution of the molten pool in the WAAM is influenced by multiple driving forces,an analysis of buoyancy,electromagnetic force,surface tension,arc pressure,and arc shear stress is conducted.The impact of these models on fluid flow and surface deformation of the molten pool is evaluated.Subsequently,three metal transition models are summarized,including utilizing a velocity inlet filled with liquid metal,incorporating a spherical mass source term at a designated position,and establishing a solid metal welding wire directly.Finally,the commonly employed gas-liquid interface tracking method is introduced.

关 键 词：电弧增材制造 传热传质 数值模拟 熔池行为 

分 类 号：TG444[金属学及工艺—焊接]