搅拌摩擦增材制造技术研究现状与发展趋势

Research status and development trend of friction stir additive manufacturing technology

  • 摘要: 现有的高能束增材制造技术在成形大型高性能金属构件时存在适用材料范围有限、能源利用率低以及成形件各向异性等工艺特点,搅拌摩擦增材制造是近年来发展起来的一项新型固相增材制造技术,其无液态金属熔凝过程的成形特征为铝合金、镁合金等易氧化轻质合金的高性能快速制备提供了新的增材制造途径。文中首先指出现有高性能金属构件增材制造技术应用的局限性,重点介绍搅拌摩擦增材制造技术的工艺原理、性能优势及应用现状。综述了国内外所开展的主要搅拌摩擦增材制造技术现状,包括同轴送料式、预置料式等类别,进而展示了搅拌摩擦增材制造技术在轻质大型结构件增材制造及特征结构添加,梯度材料与涂层制备,缺陷损伤修复及新型复合材料制备等方面的应用潜力。最后,对搅拌摩擦增材制造技术的发展趋势进行了展望。通过文中综述,以期推动该技术在国内航空航天等领域大型轻质材料构件的制备方面实现应用。创新点: (1)为解决现有激光/电子束等高能束增材制造技术在轻质材料构件应用方面的局限性,文中对搅拌摩擦增材制造这一新型固相增材制造技术开展调研分析,其无液态金属熔凝的成形特性使得制件不会形成与快速凝固相关的缺陷,如孔隙率、热烈纹、元素偏析、稀释、微细分散氧化物聚集以及高残余应力,具有更高成形效率、更大成形尺寸、更优的力学性能。(2)文中通过对搅拌摩擦增材制造技术的工艺特性与应用现状分析,总结出了该技术在轻质大型结构件增材制造、特征结构添加、梯度材料与涂层制备、缺陷损伤修复及新型复合材料制备等方面具备较大的应用潜力。

     

    Abstract: Additive friction stir deposition was a new solid phase additive manufacturing technology developed in recent years. This paper briefly described the limitations of the traditional high-energy beam additive manufacturing technology for forming high-performance metal structural parts and the technical advantages of additive friction stir deposition technology. The main types of additive friction stir deposition technologies developed at home and abroad were summarized, including coaxial feed, preset feed, cold spraying compound friction stir, and consumable friction stir tool additive manufacturing, among which the research on bar coaxial feed developed by MELD company was the most advanced. Furthermore, the applications of additive friction stir deposition technology were presented such as in manufacturing and feature addition of lightweight and large structural parts, preparation of gradient materials and coatings, defect repair and new composite materials. Finally, the development trend of additive friction stir deposition technology was prospected.Highlights: (1) In order to solve the application limitation of high energy beam additive manufacturing technology on the lightweight material member, we proposed the additive friction stir deposition which was a new type of solid phase toughening material manufacturing technology, it had no liquid metal forming characteristics in making parts, so it had not forming defects associated with rapid solidification, such as porosity, crack, element segregation, dilution, fine dispersed oxide aggregation and high residual stress, with higher forming efficiency, larger forming size and better mechanical properties.(2) In this paper, by analyzing the process characteristics and application status of additive friction stir deposition, it was concluded that this technology had great application potential in the additive manufacturing of lightweight and large structural parts, the addition of characteristic structures, the preparation of gradient materials and coatings, defect damage repair and the preparation of new composite materials.

     

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