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Abstract:
At present, Al-Cu-Mg-Ag heat-resistant alloys have become suitable materials for lightweight heat-resistant structures of high-speed crafts. Wire arc direct energy deposition (WA-DED) technology offers a suitable solution to the great challenge of integrated rapid manufacturing of large-complex Al-Cu-Mg-Ag alloy components. Unfortunately, there are few reports on the use of WA-DED technology for the fabrication of Al-Cu-Mg-Ag alloys, and the arc-deposition characteristics of Al-Cu-Mg-Ag alloys are not yet clear. In this work, the droplet transition features and arc characteristics of Al-Cu-Mg-Ag alloy during different Cold Metal Transfer (CMT) modes were investigated to illustrate the special deposit characteristics induced by its unique material properties. The surface tension coefficient of Al-Cu-Mg-Ag alloys at certain high temperatures was quantitatively calculated. The common 2319 alloy with similar Al-Cu content was specifically used as a reference to better reflect the deposit characteristics of Al-Cu-Mg-Ag alloy. The results show that the surface tension coefficient of the Al-Cu-Mg-Ag alloy is 5.6 % lower than that of 2319 alloy in the temperature interval from 1400 to 1650 degrees C. Al-Cu-Mg-Ag alloy is more prone to produce more Mg and Ag vapors with low ionization energies during WA-DED, which promotes stable burning of the arc and improves the electrical conductivity of the arc atmosphere, with a slight decrease in voltage during deposition, despite the increase in arc length. The more stable arc atmosphere enables the more uniform droplet transition period and the more stable and smooth transition process of droplets, while the lower surface tension coefficient facilitates the flow of the molten pool to promote the formation of a smoother deposited layer surface. These promising results will contribute to the application of WA-DED for the efficient manufacturing of Al-Cu-Mg-Ag aerostructural components.
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JOURNAL OF MANUFACTURING PROCESSES
ISSN: 1526-6125
Year: 2024
Volume: 131
Page: 1514-1530
6 . 2 0 0
JCR@2022
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ESI Highly Cited Papers on the List: 0 Unfold All
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30 Days PV: 4
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