铝合金多层多道摩擦辊压增材制造：面向大型复杂构件

刘海滨; 侯润; 吴程浩; 谢瑞山; 陈树君

doi:10.1007/s12613-024-2945-1

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文章导航 > 矿物冶金与材料学报（英文） > 2024 > 一校

Haibin Liu, Run Hou, Chenghao Wu, Ruishan Xie, and Shujun Chen, Multi-layer multi-pass friction rolling additive manufacturing of Al alloy: Toward complex large-scale high-performance components, Int. J. Miner. Metall. Mater.,(2024). https://doi.org/10.1007/s12613-024-2945-1

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Haibin Liu, Run Hou, Chenghao Wu, Ruishan Xie, and Shujun Chen, Multi-layer multi-pass friction rolling additive manufacturing of Al alloy: Toward complex large-scale high-performance components, Int. J. Miner. Metall. Mater.,(2024). https://doi.org/10.1007/s12613-024-2945-1

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研究论文

铝合金多层多道摩擦辊压增材制造：面向大型复杂构件

1)
北京工业大学机械与能源工程学院, 北京 100124, 中国
2)
北京工业大学重庆研究院, 重庆 401121, 中国

通讯作者:
谢瑞山 E-mail: xiers@bjut.edu.cn

文章亮点

(1) 开发了铝合金多层多道固相摩擦辊压增材制造方法

(2) 实现了搭接重叠区致密的微观结构及优异的力学性能

(3) 阐明了多层多道搭接区材料流动机理与微观组织形成机理

中文摘要

摩擦辊压增材制造（FRAM）是制备高性能铝合金构件的理想制造方法，但目前包含FRAM在内的大部分固相摩擦增材制造技术仅能制造简单的单壁墙构件。本文旨在开发FRAM多层多道沉积方法,以突破成形零件宽度的限制。本文采用6061和5052铝合金异种材料进行相互标记，研究了多层多道沉积时相邻层与相邻道之间材料流动行为，系统评价了多层多道搭接区的微观组织与力学性能。结果表明，搭接中间区域相邻层间及相邻道之间均形成机械互锁结构，边缘区内侧形成包裹结构，外侧形成峰状结构。工具头的二次摩擦辊压导致搭接区材料发生不同程度的横向流动和塑性变形，使搭接左右边缘区再结晶程度最高，搭接中间区次之，非搭接区最低。搭接区域沿不同方向的抗拉强度均能达到单壁墙构件强度的90%以上。本研究证明了FRAM多层多道次沉积时重叠区表面虽有凹凸不平的沟槽，但在下一层沉积时可被塑化材料的流动所填充，从而保证了搭接重叠区致密的微观结构和优异的力学性能。本文通过FRAM多层多道沉积克服了固相沉积样件宽度的限制，为未来制备航空航天大型、复杂、高性能构件奠定了基础。

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Research Article

Multi-layer multi-pass friction rolling additive manufacturing of Al alloy: Toward complex large-scale high-performance components

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Abstract

Abstract

At present, the emerging solid-phase friction-based additive manufacturing technology, including friction rolling additive manufacturing (FRAM), can only manufacture simple single-pass components. In this study, multi-layer multi-pass FRAM-deposited aluminum alloy samples were successfully prepared using a non-shoulder tool head. The material flow behavior and microstructure of the overlapped zone between adjacent layers and passes during multi-layer multi-pass FRAM deposition were studied using the hybrid 6061 and 5052 aluminum alloys. The results showed that a mechanical interlocking structure was formed between the adjacent layers and the adjacent passes in the overlapped center area. Repeated friction and rolling of the tool head led to different degrees of lateral flow and plastic deformation of the materials in the overlapped zone, which made the recrystallization degree in the left and right edge zones of the overlapped zone the highest, followed by the overlapped center zone and the non-overlapped zone. The tensile strength of the overlapped zone exceeded 90% of that of the single-pass deposition sample. It is proved that although there are uneven grooves on the surface of the overlapping area during multi-layer and multi-pass deposition, they can be filled by the flow of materials during the deposition of the next layer, thus ensuring the dense microstructure and excellent mechanical properties of the overlapping area. The multi-layer multi-pass FRAM deposition overcomes the limitation of deposition width and lays the foundation for the future deposition of large-scale high-performance components.
- aluminum alloy;
- additive manufacturing;
- solid-state;
- friction stir welding;
- multi-layer multi-pass

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