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学者姓名：蒋凡
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Abstract ：
Functionally graded materials (FGMs), which constitute a new type of composite material, have received considerable attention in industry because of the spatial gradient of their composition and the microstructure-induced gradient in their material performance, which make them better suited for high-performance multifunctional applications. Additive manufacturing (AM) has become one of the most promising techniques for the manufacture of materials and structures because of its high flexibility. The combination of advanced materials (FGMs) and advanced manufacturing methods (AM) is expected to facilitate the further development of such engineering materials. In this paper, the definition, historical development and material gradient types of FGMs are introduced. The classification, process principle and typical research results of the AM of metal FGMs are summarized and discussed. In particular, the research status of wire and arc additive manufacture (WAAM), which is more suitable for the preparation of large-scale metal FGMs, is reviewed in detail according to the types of FGMs, and a double-wire bypass plasma arc additive manufacturing technique, which is suitable for inducing a gradient along the direction of single-pass cladding, is proposed. On the basis of this summary of the important achievements made to date, future research is proposed.
Keyword ：
functionally graded additive manufacturing functionally graded additive manufacturing material gradient type material gradient type wire and arc additive manufacture (WAAM) wire and arc additive manufacture (WAAM) functionally graded materials (FGMs) functionally graded materials (FGMs)
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| GB/T 7714 | Zhang, Ruiying , Jiang, Fan , Xue, Long et al. Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials [J]. | CRYSTALS , 2022 , 12 (6) . |
| MLA | Zhang, Ruiying et al. "Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials" . | CRYSTALS 12 . 6 (2022) . |
| APA | Zhang, Ruiying , Jiang, Fan , Xue, Long , Yu, Junyu . Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials . | CRYSTALS , 2022 , 12 (6) . |
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Abstract ：
A novel bypass coupling variable polarity plasma arc was proposed to achieve the accurate adjusting of heat and mass transfer in the welding and additive manufacturing of aluminum alloy. However, the physical characteristics and decoupled transfer behavior remain unclear, restricting its application and development. A three-dimensional model of the bypass coupling variable polarity plasma arc was built based on Kirchhoff's law, the main arc and the bypass arc are coupled by an electromagnetic field. The model of current attachment on the tungsten electrode surface is included for simulating different heating processes of the EP and EN phases in the coupling arc. The distribution of temperature field, flow field, and current density of the bypass coupling variable polarity plasma arc was studied by the three-dimensional numerical model. The heat input on the base metal under different current conditions is quantified. To verify the model, the arc voltages are compared and the results in simulation and experiment agree with each other well. The results show that the radius of the bypass coupling arc with or without bypass current action on the base metal is different, and the flow vector of the bypass coupling arc plasma with bypass current is larger than the arc without bypass current. By comparing the heat transfer on the electrodes' boundary under different current conditions, it is found that increasing the bypass current results in the rise in heat input on the base metal. Therefore, it is concluded that using bypass current is unable to completely decouple the wire melting and the heat input of the base metal. The decoupled degree of heat transfer is one of the important factors for accurate control in the manufacturing process with this coupling arc.
Keyword ：
numerical analysis numerical analysis bypass coupling VPPA bypass coupling VPPA decoupled heat transfer decoupled heat transfer physical characteristics physical characteristics
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| GB/T 7714 | Jiang, Fan , Miao, Qi , Xu, Bin et al. Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc [J]. | MATERIALS , 2022 , 15 (9) . |
| MLA | Jiang, Fan et al. "Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc" . | MATERIALS 15 . 9 (2022) . |
| APA | Jiang, Fan , Miao, Qi , Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu , Lin, Sanbao et al. Numerical Analysis of Physical Characteristics and Heat Transfer Decoupling Behavior in Bypass Coupling Variable Polarity Plasma Arc . | MATERIALS , 2022 , 15 (9) . |
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Abstract ：
Droplet state and transition process directly determine the forming quality of deposited layer in wire and arc additive manufacturing(WAAM). In this study, an in-situ measurement system of the droplet state (temperature, velocity and mass) at plasma arc was established. An innovative staged heating method was proposed to reduce the measuring error of droplet temperature caused by the plasma arc. Meanwhile, a trajectory fitting method was studied to predict the droplet velocity, because droplet morphology was difficult to keep consistent during the transferring process. Then, the effect of current and plasma gas rate on the droplet state measurement were studied. This study will provide an effective measurement method for the droplet state in the high temperature plasma arc environment.
Keyword ：
PAW (Plasma Arc Welding) PAW (Plasma Arc Welding) Droplet temperature Droplet temperature Droplet velocity Droplet velocity Droplet mass Droplet mass Aluminum alloys Aluminum alloys
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| GB/T 7714 | Li, Cheng , Jiang, Fan , Xu, Bin et al. In-situ measurement of the droplet temperature, velocity and mass under plasma arc [J]. | MEASUREMENT , 2022 , 202 . |
| MLA | Li, Cheng et al. "In-situ measurement of the droplet temperature, velocity and mass under plasma arc" . | MEASUREMENT 202 (2022) . |
| APA | Li, Cheng , Jiang, Fan , Xu, Bin , Zhang, Guokai , Chen, Shujun , Yan, Zhaoyang et al. In-situ measurement of the droplet temperature, velocity and mass under plasma arc . | MEASUREMENT , 2022 , 202 . |
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Abstract ：
This study investigated heat and mass transfer as well as the effect of gravity on keyhole formation in the molten pool of keyhole plasma arc welding. The flow trajectory of the molten pool was obtained via high-speed camera images illuminated by a laser light system, and the temperature distribution was obtained using an infrared thermal camera. The experimental results showed that the molten metal flowed rearward and downward at the top surface of the weld pool and thereafter to the rear side of the keyhole. There are two types of reverse flow of molten metal on the rear side of the keyhole. The different welding positions had minimal effect on the flow pattern; however, the flow velocities were different. Further, for the temperature distribution, although the keyhole front side yielded a similar high-temperature area under different welding positions, the area of the high temperature on the keyhole rear side in the vertical position welding was much larger than that in the flat position. Consequently, the influence of the force on the keyhole molten pool was evaluated, and the flow pattern of the molten pool was found to be dominated by the sheer force. Moreover, the flow velocity and solidification morphology of the molten pool were affected by the gravity at different welding positions. In addition, the correlation mechanism of the temperature distribution, flow, and solidification morphology of the keyhole molten pool was analyzed using the combined action of shear force and gravity, which further revealed the mechanism of the influence of gravity on the keyhole welding process.(c) 2022 Elsevier Ltd. All rights reserved.
Keyword ：
The temperature distribution The temperature distribution VPPA welding VPPA welding Keyhole welding in different positions Keyhole welding in different positions Weld pool flow Weld pool flow Aluminum alloy Aluminum alloy
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| GB/T 7714 | Chen, Shujun , Liu, Jingbo , Jiang, Fan et al. Gravity effects on temperature distribution and material flow in the keyhole pool of VPPA Al welding [J]. | INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER , 2022 , 191 . |
| MLA | Chen, Shujun et al. "Gravity effects on temperature distribution and material flow in the keyhole pool of VPPA Al welding" . | INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER 191 (2022) . |
| APA | Chen, Shujun , Liu, Jingbo , Jiang, Fan , Xu, Bin , Zhang, Guokai , Li, Bo . Gravity effects on temperature distribution and material flow in the keyhole pool of VPPA Al welding . | INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER , 2022 , 191 . |
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Abstract ：
In this paper, a heat transfer model of the filler wire in twin-body plasma arc welding (TPAW) was established. The total power transferred to the filler wire included anode effect power, resistance power and plasma arc power. The influences of the wire current, wire extension and plasma gas flow rate on the power transferred to the filler wire were studied using the location of the molten region of the filler wire as the characteristic parameter. The studies showed that the anode effect power caused by the increase in wire current can increase the total power transferred to the filler wire by 50 % or more while the current flowing through the tungsten electrode of the plasma torch remains constant. This is confirmed by analyzing the weld shape under different wire currents. The resistive heating of the wire excision is not a major component of the total power transferred to the filler wire, and the wire extension can be set to a reasonably wide range of values. There was a threshold value for the influence of the plasma gas flow rate on plasma arc power. When the plasma gas flow rate was greater than the threshold value, plasma arc power remained nearly constant as the plasma gas flow rate increased. Therefore, the total power transferred to filler wire in TPAW was composed of anode effect power and plasma arc power. © 2021 The Society of Manufacturing Engineers
Keyword ：
Wire Wire Flow of gases Flow of gases Heat transfer Heat transfer Plasma welding Plasma welding Plasma torches Plasma torches Fillers Fillers Anodes Anodes Flow rate Flow rate Electric welding Electric welding Hard facing Hard facing Electric arcs Electric arcs
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| GB/T 7714 | Zhang, Ruiying , Jiang, Fan , Chen, Shujun . Power transferred to the filler wire in twin-body plasma arc welding [J]. | Journal of Manufacturing Processes , 2021 , 62 : 566-576 . |
| MLA | Zhang, Ruiying et al. "Power transferred to the filler wire in twin-body plasma arc welding" . | Journal of Manufacturing Processes 62 (2021) : 566-576 . |
| APA | Zhang, Ruiying , Jiang, Fan , Chen, Shujun . Power transferred to the filler wire in twin-body plasma arc welding . | Journal of Manufacturing Processes , 2021 , 62 , 566-576 . |
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Abstract ：
This study aims to enhance the localized energy of the plasma arc to meet the requirement of thick metal plate welding. To achieve this, a novel hybrid heat source by coaxial arranging the laser and plasma arc was proposed, named laser-enhanced plasma arc (LPA). This special torch combines the two kind sources by a tubular tungsten electrode which the laser passes through, use laser to heat localized plasma arc to modify the energy distribution. The three-dimensional temperature field was measured to clarify the effect of laser on plasma arc energy distribution and the absorption characteristics of laser by plasma arc. The numerical simulation model was established to reveal the influence mechanism. Results show that there is a high laser absorption region in the plasma arc, and it exists obvious effects of plasma arc pressure and temperature on laser absorption rate. The location and size of the high laser absorption region change as the welding parameters because the temperature and pressure of plasma arc change. The results also substantiate that the hybrid source energy can be adjusted locally to increase the effective flame length of the plasma arc by changing the laser energy and plasma arc parameters, which is beneficial for thick metal plate welding. This study aims to enhance the localized energy of the plasma arc to meet the requirement of thick metal plate welding. To achieve this, a novel hybrid heat source by coaxial arranging the laser and plasma arc was proposed, named laser-enhanced plasma arc (LPA). This special torch combines the two kind sources by a tubular tungsten electrode which the laser passes through, use laser to heat localized plasma arc to modify the energy distribution. The three-dimensional temperature field was measured to clarify the effect of laser on plasma arc energy distribution and the absorption characteristics of laser by plasma arc. The numerical simulation model was established to reveal the influence mechanism. Results show that there is a high laser absorption region in the plasma arc, and it exists obvious effects of plasma arc pressure and temperature on laser absorption rate. The location and size of the high laser absorption region change as the welding parameters because the temperature and pressure of plasma arc change. The results also substantiate that the hybrid source energy can be adjusted locally to increase the effective flame length of the plasma arc by changing the laser energy and plasma arc parameters, which is beneficial for thick metal plate welding.
Keyword ：
Novel heat source Novel heat source Local energy adjustment Local energy adjustment Heat transfer of laser to arc Heat transfer of laser to arc Laser-enhanced plasma arc Laser-enhanced plasma arc
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| GB/T 7714 | Jiang, Fan , Wang, Shuo , Xu, Bin et al. Local energy adjustment mechanism in a novel laser-enhanced plasma arc heat source [J]. | INTERNATIONAL JOURNAL OF THERMAL SCIENCES , 2021 , 168 . |
| MLA | Jiang, Fan et al. "Local energy adjustment mechanism in a novel laser-enhanced plasma arc heat source" . | INTERNATIONAL JOURNAL OF THERMAL SCIENCES 168 (2021) . |
| APA | Jiang, Fan , Wang, Shuo , Xu, Bin , Cheng, Wei , Ma, Xinqiang , Chen, Shujun . Local energy adjustment mechanism in a novel laser-enhanced plasma arc heat source . | INTERNATIONAL JOURNAL OF THERMAL SCIENCES , 2021 , 168 . |
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Abstract ：
The metal transfer behaviour of slant feature of thin-walls fabricated by cold metal transfer (CMT) process in step-over deposition mode was observed by high speed camera. A slanted short circuiting transfer (SSCT) was generated during deposition and then analysed by asymmetrical magnetic and force model, complicating metal transfer behaviour in comparison with conventional deposition process. The SSCT allowed the droplet to transfer obliquely into the molten pool on previous layer, owing to the pushing force generated by unevenly distributed electromagnetic field in asymmetrical deposition model. The surface tension between wire and liquid metal is the most important force that retarded droplet transfer. The retraction force and electromagnetic force are the main forces to promote droplet transition. The positive forces that promote droplet transfer process can be arranged as Fem > Fr > Fg. The wall width was mainly affected by wire feed speed and the inclined angle can be significantly increased with increasing step-over distance.
Keyword ：
Additive manufacturing Additive manufacturing Step-over deposition Step-over deposition Wire feed speed Wire feed speed Slant feature Slant feature Metal transfer Metal transfer
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| GB/T 7714 | Yan, Zhaoyang , Zhao, Yun , Jiang, Fan et al. Metal transfer behaviour of CMT-based step-over deposition in fabricating slant features [J]. | JOURNAL OF MANUFACTURING PROCESSES , 2021 , 71 : 147-155 . |
| MLA | Yan, Zhaoyang et al. "Metal transfer behaviour of CMT-based step-over deposition in fabricating slant features" . | JOURNAL OF MANUFACTURING PROCESSES 71 (2021) : 147-155 . |
| APA | Yan, Zhaoyang , Zhao, Yun , Jiang, Fan , Chen, Shujun , Li, Fang , Cheng, Wei et al. Metal transfer behaviour of CMT-based step-over deposition in fabricating slant features . | JOURNAL OF MANUFACTURING PROCESSES , 2021 , 71 , 147-155 . |
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Abstract ：
Lightweight manufacturing reduces energy consumption and protects the environment; therefore, it offers an important direction of development in engineering. Variable polarity plasma arc (VPPA) welding is a light gauge aluminum and magnesium alloy joining technology capable of the highly efficient welding of medium-thickness metals via the keyhole effect, and without the complex pre-processing required by traditional methods. However, the stability of the keyhole weld pool is easily lost, resulting in a much narrower parameter window than that of conventional methods. Here, through keyhole morphology analysis and x-ray in situ imaging experiments, we reveal the material flow behavior, the mechanism behind the stability of the keyhole weld pool, and the reason for the very narrow process parameter window in VPPA welding processes. We discovered that the polarity pressure difference of the plasma arc, which is induced by the keyhole boundary shape and plasma arc intensity, drives the flow pattern to the top side of the keyhole, which is beneficial for keyhole filling and the formation of a stable weld bead. The influence of the difference in plasma arc pressure and the keyhole boundary on the flow field revealed in this study may guide the optimization process of light metal joining to achieve the highly efficient and defect-free manufacturing of large and complex structures. © 2021 Author(s).
Keyword ：
Energy utilization Energy utilization Electric welding Electric welding Flow fields Flow fields Aluminum alloys Aluminum alloys Plasma welding Plasma welding Magnesium alloys Magnesium alloys Joining Joining Manufacture Manufacture Welds Welds Flow patterns Flow patterns
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| GB/T 7714 | Xu, Bin , Chen, Shujun , Tashiro, Shinichi et al. Physical mechanism of material flow in variable polarity plasma arc keyhole welding revealed by in situ x-ray imaging [J]. | Physics of Fluids , 2021 , 33 (1) . |
| MLA | Xu, Bin et al. "Physical mechanism of material flow in variable polarity plasma arc keyhole welding revealed by in situ x-ray imaging" . | Physics of Fluids 33 . 1 (2021) . |
| APA | Xu, Bin , Chen, Shujun , Tashiro, Shinichi , Jiang, Fan , Tanaka, Manabu . Physical mechanism of material flow in variable polarity plasma arc keyhole welding revealed by in situ x-ray imaging . | Physics of Fluids , 2021 , 33 (1) . |
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Abstract ：
The microstructure, texture, and mechanical properties of the asymmetric welded joint in variable polarity plasma arc (VPPA) welding were studied and discussed in this paper. The asymmetric welded joint was obtained through horizontal welding, where the effect of gravity caused asymmetric material flow. The results showed that the grain size and low angle grain boundary (LAGB) at both sides of the obtained welded joint were asymmetric; the grain size differed by a factor of 1.3. The average grain size of the Base Metal (BM), Lower-weld zone (WZ) and Upper-WZ were 25.73 +/- 1.25, 37.87 +/- 1.89 and 49.92 +/- 2.49 mu m, respectively. There is discrepancy between the main textures in both sides of the welded joint. However, the effect of asymmetric metal flow on the weld texture was not significant. The micro-hardness distribution was inhomogeneous, the lowest hardness was observed in regions with larger grain sizes and smaller low angle grain boundary. During tensile strength tests, the specimens fractured at the position with the lowest hardness although it has reached 89.2% of the strength of the BM. Furthermore, the effect of asymmetric metal flow and underlying causes of asymmetric weld properties in VPPA horizontal welding have been discussed and analyzed.
Keyword ：
VPPA VPPA microstructure microstructure material flow material flow tensile strength tensile strength asymmetric weld asymmetric weld
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| GB/T 7714 | Yan, Zhaoyang , Chen, Shujun , Jiang, Fan et al. Effect of Asymmetric Material Flow on the Microstructure and Mechanical Properties of 5A06 Al-Alloy Welded Joint by VPPA Welding [J]. | METALS , 2021 , 11 (1) . |
| MLA | Yan, Zhaoyang et al. "Effect of Asymmetric Material Flow on the Microstructure and Mechanical Properties of 5A06 Al-Alloy Welded Joint by VPPA Welding" . | METALS 11 . 1 (2021) . |
| APA | Yan, Zhaoyang , Chen, Shujun , Jiang, Fan , Zheng, Xing , Tian, Ooi , Cheng, Wei et al. Effect of Asymmetric Material Flow on the Microstructure and Mechanical Properties of 5A06 Al-Alloy Welded Joint by VPPA Welding . | METALS , 2021 , 11 (1) . |
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Abstract ：
A variable-polarity plasma arc (VPPA) is an effective energy source for the welding of thick aluminum alloy plates. However, the mechanisms influencing the fluid flow and the inhomogeneous distribution associated with thick-plate VPPA welding remain unclear, restricting the application of this technology in welding of thick aluminum alloys. Here, the relationship between the microstructure of the weld bead, energy transfer, and fluid flow is clarified by combining in situ three-dimensional x-ray imaging and multi-physics modeling. We find that heat conduction at the keyhole wall is the main factor influencing the morphology of the weld pool. The plasma arc pressure hinders the upward flow of liquid metal, while shear forces promote this flow. This causes the metal close to the weld pool surface to flow slowly, while that inside the weld pool has much higher velocity. It is also concluded that the large crystal size observed in the lower layer of the weld is partly caused by heat treatment from the upper layer of the thick plate. An eddy with a high flow velocity to the rear of the weld pool destroys the crystal-growth process, and this is considered to be one of the reasons for fine crystals appearing in the upper part of the weld. The mechanisms revealed here will help us to guide the use of VPPA technology in the production of stable, high-quality welding of thick aluminum alloys. Published under an exclusive license by AIP Publishing.
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| GB/T 7714 | Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu et al. Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates [J]. | PHYSICS OF FLUIDS , 2021 , 33 (8) . |
| MLA | Xu, Bin et al. "Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates" . | PHYSICS OF FLUIDS 33 . 8 (2021) . |
| APA | Xu, Bin , Tashiro, Shinichi , Tanaka, Manabu , Jiang, Fan , Chen, Shujun . Physical mechanisms of fluid flow and joint inhomogeneity in variable-polarity plasma arc welding of thick aluminum alloy plates . | PHYSICS OF FLUIDS , 2021 , 33 (8) . |
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