Numerical analysis of aluminum alloy fused coating process
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TECHNICAL PAPER
Numerical analysis of aluminum alloy fused coating process Guangxi Zhao1,2 · Jun Du2 · Zhengying Wei2 · Siyuan Xu2 · Ruwei Geng2 Received: 10 March 2019 / Accepted: 14 August 2020 / Published online: 19 August 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020
Abstract Aiming at the difficulties in the additive manufacturing process of aluminum alloy, the aluminum alloy fused coating process with arc preheating is proposed. A three-dimensional transient numerical model is established based on the finite difference method. The evolution process of melt flow and spreading is studied, and the interaction effects between the molten fluid and the driving forces were analyzed. The effect of the different distance between the nozzle and the tungsten electrode on the coating process is computed. It is found that when the distance is less than 8 mm, the substrate cannot directly absorb the energy of the arc and the preheating effect of the front heat source is gradually lost. The aluminum alloy melt spread is blocked and spread sideways, and the contour profile of the coating layer begins to become irregular. When the distance is greater than 14 mm, spheroidization occurs at the position of the starting end of the coating layer. Through the analysis of the dimensionless numbers, it is found that in the early stage of the fused coating process, the heat lost by heat conduction in the molten pool is more than that of convection and the influence order of partial driving forces is surface tension > Lorentz force > buoyancy. Keywords Fused coating · Aluminum alloy · Additive manufacturing · Arc preheating
1 Introduction With the increasing demand for large-scale and lightweight components in industrial production, the use of aluminum alloys has been greatly increased. In addition to the typical aerospace industry, aluminum alloys also play an important role in railway transportation and automobile manufacturing [1, 2]. Because of the advantages of low density, high specific strength and good corrosion resistance of aluminum alloy [3], the research on additive manufacturing technology of aluminum alloy has become one of the hotspots. Metal additive manufacturing technology mainly includes selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EBM), wire and arc additive manufacturing (WAAM) [4]. The following difficulties exist
Technical Editor: Lincoln Cardoso Brandao. * Guangxi Zhao [email protected] 1
School of Mechanical Engineering, Shandong University of Technology, Zibo, Shandong, China
School of Mechanical Engineering, Xi’an JiaoTong University, Xi’an, Shaanxi, China
2
in the application of the mentioned additive manufacturing technologies in aluminum alloy: Firstly, in the common laser wavelength range, aluminum alloys have high reflectivity, and the coupling of heat source and material is challenging for laser-based additive manufacturing processes [5]. Secondly, many aluminum alloys contain solute additives and their vapor pressu
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