Abstract:
Objective This study focuses on controlling the single-track cladding morphology and suppressing end defects in wire-fed laser additive manufacturing of 4043 aluminum alloy. The coupling effects of laser power, wire feeding rate, and travel speed are investigated, and a dynamic transition zone regulation strategy is proposed.
Methods By regulating welding parameters such as laser power, wire feeding rate and travel speed, influence of these parameters on cladding morphology and defects is analyzed. A collaborative control method for the front and rear transition zones is proposed, the front transition zone uses preheating to reduce wetting angle, while the rear transition zone uses power reduction, increasing travel speed and wire feeding optimization to achieve active separation of wire tip, thereby suppressing end adhesion and collapse defects.
Results Results indicate that increasing laser power expands cladding width while reducing its height. A wire feeding rate exceeding 4.5 m/min tends to induce lack-of-fusion defects, and a travel speed of 3 m/min triggers hump defects due to Rayleigh instability. After optimization of dynamic transition zone, adhesion rate decreases significantly, and collapse depth is controlled within 0.08 mm. Compared to traditional methods, this strategy demonstrates enhanced defect suppression.
Conclusion Dynamic transition zone regulation strategy can effectively suppress end defects in wire-fed laser additive manufacturing process of 4043 aluminum alloy and improve forming quality, providing theoretical and process optimization insights for efficient additive manufacturing of aluminum alloy.