金属增材制造中的缺陷、组织形貌和成形材料力学性能

金属增材制造是近30年发展起来的一种新型制造技术, 不同于传统的减材制造过程, 它是基于离散-堆积原理, 根据设计的三维数据模型, 逐层加工获得立体实物的制造技术, 具有近净成形、快速制造、设计自由度高等优点, 特别适用于具有复杂几何结构的高熔点金属构件的直接成形, 在航天航空、核能工业、交通运输、生物医疗等领域具有巨大的技术优势和广阔的应用前景. 本文首先介绍了3种典型的金属增材制造技术原理, 包括选区激光熔化技术、激光金属沉积技术和选区电子束熔化技术. 随后对金属增材制造中的熔合不良、气孔、裂纹等缺陷的形成机理及其控制方法进行了综述, 以激光功率、扫描速度和扫描策略等工艺参数为例阐述了工艺参数对成形构件组织形貌的影响, 同时介绍了金属增材制造技术在传统合金、高熵合金以及非晶合金等材料中的应用及其力学性能. 最后对金属增材制造在扩充可打印的合金体系、量化缺陷与残余应力对材料性能的影响、发展可预测组织形貌的模拟方法、建立金属增材制造数据库和相关标准等方向进行了展望.      

面向增材制造的应力最小化连通性拓扑优化

增材制造与拓扑优化的有机结合将极大促进高性能产品的研发,但现有基于拓扑优化的设计性能和可制造性研究多是独立开展,或常局限于传统的刚度问题,缺乏对工程中至关重要的强度问题的考虑.面向增材制造,针对协同考虑强度和可制造连通性的结构优化问题,建立了材料体积和连通性标量场约束下的结构应力最小化拓扑优化模型.针对求解过程中的不同...     

增材制造技术发展对飞机结构设计教学的影响

增材制造技术突破传统制造约束,带来飞机结构设计理念和方法的转变,成为提升飞机结构性能、降低成本的重要支撑.飞机结构设计是飞行器设计专业本科核心专业课程,培养面向增材制造的飞机结构设计人才是提高航空装备设计水平的必要内容.创新结构设计理念和多学科协同设计方法是面向增材制造结构设计人员的必备素质.北京航空航天大学飞机结构设...     

基于渐进演化策略的增材制造自支撑结构拓扑优化算法

拓扑优化和增材制造分别是先进的结构设计技术和制造技术,将拓扑优化与增材制造融合能产生显著的协同效益.增材制造存在一些独特的制造约束,研究考虑结构自支撑约束的拓扑优化算法,可以降低材料和时间成本.基于SIMP方法框架,建立显式约束函数模型表征结构的自支撑特性,并发展了相应的拓扑优化流程,通过结构渐进演化实现自支撑.研究了相应的灵敏度分析方法,可实现并行计算.提出一个指向性灵敏度过滤算子促进支撑结构演化.采用3个数值算例进行分析,验证了指向性灵敏度过滤的有效性,所有拓扑优化结果均实现了结构自支撑.与典型方法相比,优化结果的可制造性更好.     

增材制造TC4钛合金的动态力学行为研究

增材制造TC4钛合金是具有优良的力学性能和工艺性能的金属材料,在航空航天领域已得到重要应用.近年来,在塑性力学的研究中,探究应力状态对金属材料变形和失效行为的影响得到广泛关注,然而大部分的研究都是在准静态下完成的,对于中高应变率下金属材料变形失效的研究较少.本文从增材制造TC4钛合金的基本力学性能出发,考虑应力状态和应...     

面向增材制造的双蒙皮夹层结构加筋拓扑优化方法

双蒙皮夹层结构是航空航天装备中的特殊承力结构,其典型代表为发动机尾喷管中的同步环构件。近年来,增材制造技术为该类薄壁结构的创新型设计提供了有利条件。但增材制造有其特殊的工艺要求,基于传统拓扑优化得到的设计结果往往存在大量的悬空区域,无法直接应用于增材制造工艺。因此,需要在优化设计阶段统筹考虑结构的力学性能和自支撑工艺约束。针对上述问题,本文提出了一种面向增材制造的双蒙皮夹层薄壁结构加筋拓扑优化方法,可在一次优化中同时得到优化的加筋布局和非均匀点阵分布,从而解决悬空结构的支撑问题,确保优化结果的工艺可达性。为了平衡计算成本和分析精度,本文采用渐进均匀化方法来求解不同类型单胞等效弹性性能,以适应不同复杂单胞构型。基于上述方法,本文给出了某发动机同步环结构的拓扑优化算例,结果表明,本文优化设计方法可以实现双蒙皮夹层结构中夹层加筋和点阵的共同优化,为航空航天装备中发动机同步环结构轻量化设计提供了思路。     

金属增材制造过程中材料微观组织演化的模拟研究

金属增材制造是集设计、制造一体化的一种新型金属构件制造技术, 在航天航空、交通运输、生物医疗等领域具有广阔的应用前景. 金属增材制造材料的力学性能与其材料微观组织密切相关. 因此, 发展金属增材制造过程中材料微观组织的模拟方法, 有助于指导和优化金属增材制造的工艺参数和流程, 从而制备出性能优异的金属材料. 本文发展了基于连续体假设的热传导模型与元胞自动机相结合的模拟方法, 并利用生死单元方法, 考虑晶粒的重熔和再生长过程, 解决了金属增材制造中多层粉末制造的数值模拟问题. 本文采用该方法模拟了镍基合金IN718、不锈钢316L和高熵合金FeCoCrNiMn的增材制造过程, 并获得了这些增材制造合金的典型材料微观组织, 其模拟结果与实验结果相吻合. 同时, 将该方法拓展到三维尺度的模拟, 研究了镍基合金IN718增材制造过程中三维晶粒的形核和生长. 最后, 对金属增材制造过程中材料微观组织演化的模拟研究中的主要问题进行了总结和展望.      

金属增材制造中的关键力学问题与前沿计算技术主题序

增材制造(亦称“3D打印”)是以数字模型为基础, 将材料逐层堆积制造出实体构件的新兴制造技术, 涉及力学、光学、材料、机械、控制、计算机、软件等学科的交叉融合, 已成为现代制造业最具代表性的颠覆性技术, 也是《中国制造2025》规划的重要发展方向. 金属增材制造是3D打印技术的一个主要分支, 一般常采用高能束(激光、电子束等)作为输入热源, 通过熔化离散金属材料(粉材、丝材)进行逐层叠加打印制件, 从而弥补传统减材和等材制造的不足, 已在航空航天、汽车电子及生物医学等众多领域取得了典型应用. 然而, 从结构设计、制造过程到性能评价, 金属增材制造涉及众多的关键力学问题亟待解决. 例如, 由于金属粉材或丝材的离散效应, 如果工艺参数选择不当, 金属3D打印产品易出现内部缺陷和表面缺陷, 从而影响打印构件的宏观力学性能及服役可靠性.      

增材制造316钢高周疲劳性能的微观力学研究

由于增材制造逐层累积的工艺特点, 其成形材料力学性能往往不同于传统减材制造材料. 在航空航天、核工业以及医疗领域中, 对增材制造材料疲劳性能的研究不足导致其很难作为主承力件使用, 这制约着增材制造技术的进一步推广使用. 本文以增材制造316钢为对象, 通过仿真手段研究其高周疲劳性能, 研究表明循环载荷下滑移带与晶界处的裂纹萌生是增材制造316钢材料发生高周疲劳的主要原因. 根据提出的微观力学模型研究了增材制造316钢的高周疲劳性能, 其中分别使用唯象学晶体塑性理论和弹塑性内聚力模型模拟晶粒和晶界的力学行为. 为了准确评估增材制造316钢的高周疲劳性能, 本文针对于晶粒和晶界分别采用Papadopoulos疲劳准则和一种基于安定性理论的介观疲劳准则同时考虑位错滑移和晶界对疲劳性能的影响. 最后, 为了验证所提微观力学模型的有效性, 本文对比了增材制造316钢和轧制316钢高周疲劳性能的仿真结果. 与实验结果相同, 仿真结果显示增材制造316钢相较于轧制316钢具有更好的高周疲劳性能.      

增材制造微结构演化及疲劳分散性计算

为了预测增材制造中工艺参数?微结构?力学性能之间的关联规律, 提出了集成离散元、相场模拟、晶体塑性有限元和极值概率理论的计算方法, 揭示了激光扫描速度对微结构演化、屈服应力和疲劳分散性的影响. 首先, 采用离散元实现了重力作用下粉床在已凝固层表面上的逐层铺设; 其次, 通过热?熔体?微结构耦合的非等温相场模拟, 获得了熔体、气孔、晶界、晶粒取向等的时空演化以及最终形成的多晶微结构; 然后, 应用晶体塑性有限元计算了增材制造多晶微结构的宏观力学响应, 并得到表征疲劳裂纹萌生驱动力的疲劳指示参数(FIP); 最后, 采用极值概率理论分析了增材制造多晶微结构的FIP极值分布规律及疲劳分散性. 以316L不锈钢选区激光熔化增材制造为例的计算结果表明: 增材制造微结构的宏观屈服强度随激光扫描速度的增加而降低, 且呈各向异性; FIP极值符合Gumbel极值分布规律, 激光扫描速度增加可降低增材制造微结构疲劳分散性, 但会导致FIP极值升高, 使得疲劳裂纹萌生驱动力增加, 疲劳寿命降低.      

Approaches in computational welding mechanics applied to additive manufacturing: Review and outlook

The development of computational welding mechanics (CWM) began more than four decades ago. The approach focuses on the region outside the molten pool and is used to simulate the thermo-metallurgical-mechanical behaviour of welded components. It was applied to additive manufacturing (AM) processes when they were known as weld repair and metal deposition. The interest in the CWM approach applied to AM has increased considerably, and there are new challenges in this context regarding welding. The current state and need for developments from the perspective of the authors are summarised in this study.     

A review on stress determination and control in metal-based additive manufacturing

Metal additive manufacturing (MAM) is an emerging and disruptive technology that builds three-dimensional (3D) components by adding layer-upon-layer of metallic materials. The complex cyclic thermal history and highly localized energy can produce large temperature gradients, which will, in turn, lead to compressive and tensile stress during the MAM process and eventually result in residual stress. Being an issue of great concern, residual stress, which can cause distortion, delamination, cracking, etc., is considered a key mechanical quantity that affects the manufacturing quality and service performance of MAM parts. In this review paper, the ongoing work in the field of residual stress determination and control for MAM is described with a particular emphasis on the experimental measurement/control methods and numerical models. We also provide insight on what still requires to be achieved and the research opportunities and challenges.     

工程力学中的互补问题:模型

对互补问题在非线性力学中的一些应用情况给出了较概括的介绍,重点放在了静态接触问题、弹塑性问题以及结构优化问题的互补模型上。将力学问题写成互补模型的好处主要有两点：一是使力学问题有更自然、更精确的数学描述;二是可以考虑用互补问题的有效和强健的数值算法来求解。     

Ill-posed problems in mechanics

The notion of ill-posed initial and boundary value problems for partial differential equations was introduced by Hadamard, who also presented the first example of an ill-posed problem for a specific partial differential equation. At the same time, there are numerous examples of ill-posed problems in any field of mechanics.Hadamard and some of his successors believed that any ill-posed problem has no physical meaning and such problems should not be posed.The present paper contains several examples of ill-posed problems. We show that if one deals with an applied problem, then overcoming the ill-posedness mathematically can help one to improve the structure in practice, which justifies the study of ill-posed problems.     

理论力学中的概率问题

讨论了含有随机变量的力学系统. 通过4个例题给出了研究力学系统概率问题的具体方法.     

Some problems in metallurgical fluid mechanics

Application of computational fluid mechanics in two areas of metallurgy is considered: solidification of liquid alloys and MHD turbulence. In the first class of problems, where the technical issue is to obtain a reasonably homogeneous composition of the cast, one has to consider not only the completely molten and solidified regions but also the “mushy zone” that is made up of small-scale dendrites, which appear between the first two regions. In the completely molten region, the composition is practically constant and the fluid is set into motion due to the inhomogeneous temperature field. In the mushy zone, on the other hand, solutal convection often dominates strongly over thermal convection. It is shown that laminar convection is of prime importance for the composition of the solidified alloy. In the second class of problems, two cases of turbulent MHD flows in cylindrical containers are considered: an electromagnetic furnace and an electromagnetic stirrer. In the electromagnetic furnace, the mean flow consists of two toroidal vortices. The mean motion in the electromagnetic stirrer is a swirling motion that is accompanied by a weak meridional circulation, which is reminiscent of that occuring in spin down phenomena. The MHD flows are computed by using large eddy simulation methodology with a new subgrid model of the Smagorinsky type that accounts for a variable mesh. Predictions from the all model computations are compared with experimental observations. In general, the agreement between theory and experiments is satisfactory.     

Fluid mechanics of turbomachines: a review

Future development of more efficient turbomachinery depends on improving understanding of the fluid mechanics. This paper reviews advances made in the last five years in calculation methods for steady flow, unsteady flows and stability, and instrumentation and its applications. Fundamental problems which need further study are also indicated     

Advances in scalable gas-phase manufacturing and processing of nanostructured solids: A review

Although the gas-phase production of nanostructured solids has already been carried out in industry for decades, only in recent years has research interest in this topic begun to increase. Nevertheless, despite the remarkable scientific progress made recently, many long-established processes are still used in industry. Scientific advancements can potentially lead to the improvement of existing industrial processes, but also to the development of completely new routes. This paper aims to review state-of-the-art synthesis and processing technologies, as well as the recent developments in academic research. Flame reactors that produce inorganic nanoparticles on industrial- and lab-scales are described, alongside a detailed overview of the different systems used for the production of carbon nanotubes and graphene. We discuss the problems of agglomeration and mixing of nanoparticles, which are strongly related to synthesis and processing. Finally, we focus on two promising processing techniques, namely nanoparticle fluidization and atomic layer deposition.