超声冲击对电弧增材制造铝合金应力及变形的影响  

Effect of ultrasonic impact on stress and deformation of aluminum alloy made by wire and arc additive manufacturing

作　　者：秦泽辉 李攀 杨东青 李晓鹏[1] Qin Zehui;Li Pan;Yang Dongqing;Li Xiaopeng(MIIT Key Laboratory of Controlled Arc Intelligent Additive Technology,Nanjing University of Science and Technology,Nanjing 210094,China)

机构地区：[1]南京理工大学受控电弧智能增材技术工业和信息化部重点实验室,江苏南京210094

出　　处：《南京理工大学学报》2025年第2期223-232,共10页Journal of Nanjing University of Science and Technology

基　　金：航空科学基金(20230011059001);中央高校基本科研业务费专项资金(30924010829)。

摘　　要：由于铝合金增材制造制备构件时,构件内部留存大量残余应力,施加超声冲击降低残余应力后可大幅提高构件性能。通过附加同步焊枪运动的超声冲击,来辅助电弧增材的过程,制造2219铝合金单层多道沉积件,并对该辅助条件下制备的沉积件的残余应力及材料变形情况进行试验测量和数值模拟,分析了同步焊枪的单超声冲击辅助对残余应力和材料变形的影响。模拟结果显示,施加同步超声冲击辅助后,沉积件内的应力得到释放,在刚沉积完的区域应力集中减小得不明显,附加超声冲击的沉积件的等效残余应力和未附加超声冲击的沉积件的等效残余应力变化趋势一致,但拉应力值明显降低,等效残余应力峰值由未附加超声冲击时的217.5 MPa下降至附加超声冲击时的163.1 MPa,沉积完成且冷却300 s后的平均等效应力值由153.12 MPa下降至114.43 MPa,残余应力下降了25.27%。实际测量得到的表面残余应力的范围由90.03~207.71 MPa下降至54.25~141.62 MPa,平均残余应力下降29.16%。试验及模拟证实,附加超声冲击辅助后铝合金构件残余应力降低,性能有效提高,应用领域得以拓宽。Due to the process of aluminum alloy additive manufacturing in the preparation of components,a large amount of residual stress remains inside the components.Applying ultrasonic impact to reduce residual stress can significantly improve the performance of the components.Assist in the process of wire and arc additive manufacturing by adding ultrasonic impact with synchronous welding gun movement to manufacture 2219 aluminum alloy single-layer and multi-channel deposited parts.And under this auxiliary condition,the residual stress and material deformation of the deposited parts prepared were experimentally measured and numerically simulated.The influence of single ultrasonic impact assistance of synchronous welding gun on residual stress and material deformation was analyzed.The simulation results show that the stress in the deposited parts is released after the application of synchronous ultrasonic impact assistance,and the stress concentration in the area just deposited is not obviously reduced.The equivalent residual stress of the deposited parts with ultrasonic impact has the same change trend as that without ultrasonic impact,but the value of tensile stress is obviously reduced.The peak value of equivalent residual stress decreases from 217.5 MPa without ultrasonic impact to 163.1 MPa with ultrasonic impact.After deposition and cooling for 300 seconds,the value of average equivalent residual stress decreases from 153.12 MPa to 114.43 MPa,the residual stress decreases by 25.27%.The stress range of surface residual stress measured in practice decreases from 90.03~207.71 MPa to 54.25~141.62 MPa,and the average residual stress decreases by 29.16%.Experiments and simulations confirm that the addition of ultrasonic impact assistance reduces residual stress in aluminum alloy components,effectively improves performance,and expands application fields.

关 键 词：电弧增材制造 2219铝合金 同步超声冲击 残余应力 有限元分析 

分 类 号：V252.4[一般工业技术—材料科学与工程]