刘静怡,李文辉,李秀红,杨胜强,温学杰,武荣穴.航空零部件的金属增材制造光整加工技术研究进展[J].表面技术,2023,52(12):20-41.
LIU Jing-yi,LI Wen-hui,LI Xiu-hong,YANG Sheng-qiang,WEN Xue-jie,WU Rong-xue.Research Progress of Finishing Technology for Aviation Parts Built by Metal Additive Manufacturing[J].Surface Technology,2023,52(12):20-41 |
| 航空零部件的金属增材制造光整加工技术研究进展 |
| Research Progress of Finishing Technology for Aviation Parts Built by Metal Additive Manufacturing |
| 投稿时间：2023-09-19 修订日期：2023-11-10 |
| DOI：10.16490/j.cnki.issn.1001-3660.2023.12.002 |
| 中文关键词: 增材制造 航空金属零部件 光整加工 表面缺陷 表面粗糙度 复杂结构 |
| 英文关键词:additive manufacturing aviation metal parts finishing processing surface defects surface roughness complex construction |
| 基金项目:国家自然科学基金(51875389、51975399、52075362);中央引导地方科技发展资金项目(YDZJSX2022B004、YDZJSX2022A020) |
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| Author | Institution |
| LIU Jing-yi | College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan 030024, China;Shanxi Key Laboratory of Precise Machining, Taiyuan 030024, China |
| LI Wen-hui | Shanxi Key Laboratory of Precise Machining, Taiyuan 030024, China;College of Aeronautics and Astronautics, Taiyuan University of Technology, Shanxi Jinzhong 030600, China |
| LI Xiu-hong | College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan 030024, China;Shanxi Key Laboratory of Precise Machining, Taiyuan 030024, China |
| YANG Sheng-qiang | College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan 030024, China;Shanxi Key Laboratory of Precise Machining, Taiyuan 030024, China |
| WEN Xue-jie | College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan 030024, China;Shanxi Key Laboratory of Precise Machining, Taiyuan 030024, China |
| WU Rong-xue | College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan 030024, China;Shanxi Key Laboratory of Precise Machining, Taiyuan 030024, China |
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| 中文摘要: |
| 增材制造具有无需模具直接制造、材料利用率高，且对于结构复杂程度不受限制等优点，广泛应用于复杂化、轻量化的航空金属零部件一体化制造。但由于增材制造成形的零部件存在较高的表面粗糙度、复杂的残余应力分布以及难以消除的孔隙缺陷，严重制约了其在工业上的大规模应用。针对高使役性能航空零部件存在的表面完整性问题，概述了金属增材制造的原理及特点，总结了金属增材制造技术在航空领域的国内外应用现状，分析了金属增材制造零部件在批量生产与实际应用过程中所面临的困难与挑战。从加工机理、加工效果、应用范围等角度，重点阐述了化学、电化学、磨粒流、滚磨、激光等光整加工技术在航空金属增材制造领域的加工适应性，并对比分析了不同光整加工技术的优缺点，探讨了多种组合技术的多能场耦合协同效应，研究内容涵盖钛合金、不锈钢、铝合金、铜合金等材料，涉及管类、格栅、点阵、薄壁、曲面、复杂型腔等零部件结构特征。最后，针对航空金属增材制造光整加工领域的未来研究方向及关键技术作出思考与展望。 |
| 英文摘要: |
| Additive manufacturing has many advantages, including shape without a mold, high material utilization, and unlimited structural complexity. It is widely used in the integrated manufacturing of complex and lightweight aviation metal parts. In recent years, with the exploration of the principle and characteristics of metal additive manufacturing technology, the variety and quality of additive manufacturing parts have been fully developed. The application status of metal additive manufacturing technology in the aviation field at home and abroad is summarized, and the difficulties and challenges faced by metal additive manufacturing parts in mass production and practical application are analyzed. At present, the application of additive manufacturing technology in the aviation field is mature abroad. Compared with foreign countries, China has also made some progress in the surface quality and mechanical properties of additive manufacturing parts. However, there are still some gaps in post-processing. The defects of additive manufacturing parts include powder adhesion, step effect, balling effect, cracks, pores, and complex residual stress distribution. Poor surface integrity affects fatigue performance and seriously restricts the large-scale application of additive manufacturing in industry. To improve the surface integrity of aviation additive manufacturing parts, this article focuses on the processing adaptability of various finishing technologies such as chemistry, electrochemistry, abrasive flow, barrel, and laser in the aviation metal additive manufacturing field. The research involves surfaces created through additive manufacturing using different materials, including titanium alloy, stainless steel, aluminum alloy, copper alloy, etc., and the influence of structural features such as tubes, grids, lattices, thin walls, curved surfaces, complex cavities, and other parts on finishing behavior. Each finishing technology’s processing mechanism and appropriate processing parameters are reviewed to determine the optimal processing strategy. The processing effects of each technology on the surface of additive manufacturing are summarized from the perspectives of surface roughness, surface hardness, micromorphology, and so on. The advantages and disadvantages of different finishing technologies are compared and analyzed. Chemical finishing and electrochemical finishing have good accessibility and usually produce no residual stress during the process, which can be applied to complex structures such as grids and arrays. However, the processing of these two finishing technologies is not very environmentally friendly, and it is difficult to accurately control the accuracy of the parts. In contrast, barrel finishing and abrasive flow machining can control the machining process very well. They usually have a high material removal rate, which can respond quickly to rough surfaces. These two finishing technologies have a long processing time and are prone to edge effects. It is necessary to control the complex flow field. Laser finishing has a high degree of automation and can be integrated with additive manufacturing systems. However, its accessibility is limited, and the processing process may increase the generation of thermal residual stress. After that, combined with the advantages and disadvantages of each finishing technology, the multi-energy field coupling synergistic effect of different combination finishing processes such as chemical-electrochemistry, mechanical-chemistry, and mechanical-electrochemistry is introduced. In the future, research on the finishing technology of aviation metal additive manufacturing parts will focus on complex features, establish a more complete theoretical framework, and lead to more innovative finishing processes. |
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