基于多能场的陶瓷颗粒增强铝基构件涂覆高效成形方法研究

为满足航空航天构件轻质高强耐磨及整体化制造需求，针对现在增材制造复合材料构件成本高、成形效率低等问题，以陶瓷颗粒增强铝基复合材料构件一体化高效成形为目标，提出电磁感应熔化和电弧复合能场作用下的熔融涂覆增材制造新工艺。建立陶瓷颗粒增强铝基构件涂覆成形数值计算模型，研究多能场下铝合金熔体和陶瓷颗粒相互作用机制，揭示熔池内增强体颗粒分散规律和均匀化机理；分析工艺参数对沉积态增强体/基体界面微区微观组织特征的影响，研究多重热循环下界面特征及微观组织的演化规律，探明不同颗粒增强体、掺杂浓度与粒径分布对界面微观组织的影响规律；表征不同工艺、颗粒参数下涂覆成形试件力学性能，分析颗粒增强铝基复合材料断裂失效形式和破坏机制；同时研究涂覆高效成形参数与表面质量适配性，改进熔融涂覆工艺，以保证在结构内部高效率填充时提高特征表面形貌质量，为轻质高性能复合材料构件高效率、低成本一体化成形提供技术支撑。

For the requirements of integrated manufacturing of lightweight composites in aerospace components, and aiming at the problem of the high cost and low forming efficiency of the existing laser additive manufacturing, a novel process of fused-coating additive manufacturing adopting arc and electromagnetic energy is put forward. Numerical models of fused-coating forming of ceramic particles reinforced aluminum-matrix components are built, and the interactions between the coated alloy melt and the ceramic particles in the multi-energy field are researched, revealing the distribution laws and homogenization mechanism of the particles in the molten pool. The effects of different process parameters on the microstructure characteristics of deposition reinforcement / matrix interface are analyzed, and the influences of multiple thermal cycles on interfacial characteristics and microstructural evolution are investigated. The effects of different particle reinforcements, concentration and particle sizes on microstructure and micro - mechanical properties are investigated. The mechanical properties of the fused-coating specimens are characterized and the failure modes and failure mechanism of the particles reinforced aluminum-matrix composites are analyzed. In order to improve the filling efficiency and the surface quality of feature surface, the adaptation between efficient forming parameters and surface quality is researched. By improving the process of fused-coating, the theoretical support of the intergrade forming of aircraft lightweight composite material components with high performance and low cost will be provided.