A Net Shape Profile Extraction Approach for Exploring the Forming Appearance of Inclined Thick-Walled Structures by Wire Arc Additive Manufacturing.

IF 3 3区 工程技术 Q2 CHEMISTRY, ANALYTICAL Micromachines Pub Date : 2024-10-16 DOI:10.3390/mi15101262
Yexing Zheng, Yongzhe Li, Yijun Zhou, Xiaoyu Wang, Guangjun Zhang
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Abstract

Wire arc additive manufacturing (WAAM) offers a viable solution for fabricating large-scale metallic parts, which contain various forms of inclined thick-walled structure. Due to the variety of heat dissipation conditions at different positions, the inclined thick-walled structure is a major challenge in fabrication that may produce collapses and defects. However, there is a lack of effective sensing method for acquiring the forming appearance of individual beads in the structure. This paper proposes a novel approach for extracting individual bead profiles during the WAAM process. The approach utilizes a structured-laser sensor to capture the morphology of the surface before and after deposition, thereby enabling an accurate acquisition of the bead profile by integrating the laser stripes. Utilizing the proposed approach, the research investigated the forming mechanism of beads in inclined thick-walled components that were fabricated by various deposition parameters. The width of the overlapping area at the overhanging feature decreased as the layer number increased, while the height of the same area increased. The height of the overlapping area in each layer increased with an increase in deposition current and decreased when the deposition speed was increased. These phenomena suggest that the heat input is a major factor that influences the formation of the overhanging feature. Both the deposition current and deposition velocity influence heat input, and thereby have an effect in enhancing the geometrical accuracy of an overhanging feature. The experimental results indicate that the proposed approach facilitates morphology change investigation, providing a sufficient reference for optimizing deposition parameters.

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利用线弧快速成型技术探索倾斜厚壁结构成型外观的净形状轮廓提取方法
线弧增材制造(WAAM)为制造包含各种形式倾斜厚壁结构的大型金属零件提供了一种可行的解决方案。由于不同位置的散热条件各不相同,倾斜厚壁结构是制造过程中的一大挑战,可能会产生塌陷和缺陷。然而,目前还缺乏有效的传感方法来获取结构中单个珠子的成型外观。本文提出了一种在 WAAM 过程中提取单个珠子轮廓的新方法。该方法利用结构化激光传感器捕捉沉积前后的表面形态,从而通过整合激光条纹准确获取微珠轮廓。利用所提出的方法,研究人员对采用不同沉积参数制造的倾斜厚壁元件中的微珠成型机制进行了研究。随着层数的增加,悬挂特征处重叠区域的宽度减小,而相同区域的高度增加。每层重叠区域的高度随着沉积电流的增加而增加,当沉积速度增加时,重叠区域的高度则降低。这些现象表明,热输入是影响悬挂特征形成的主要因素。沉积电流和沉积速度都会影响热输入,从而对提高悬挂特征的几何精度产生影响。实验结果表明,所提出的方法有助于形态变化研究,为优化沉积参数提供了充分的参考。
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来源期刊
Micromachines
Micromachines NANOSCIENCE & NANOTECHNOLOGY-INSTRUMENTS & INSTRUMENTATION
CiteScore
5.20
自引率
14.70%
发文量
1862
审稿时长
16.31 days
期刊介绍: Micromachines (ISSN 2072-666X) is an international, peer-reviewed open access journal which provides an advanced forum for studies related to micro-scaled machines and micromachinery. It publishes reviews, regular research papers and short communications. Our aim is to encourage scientists to publish their experimental and theoretical results in as much detail as possible. There is no restriction on the length of the papers. The full experimental details must be provided so that the results can be reproduced.
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