scholarly journals Research on gradient additive remanufacturing of ultra-large hot forging die based on automatic wire arc additive manufacturing technology

Author(s):  
Xiaoying Hong ◽  
Guiqian Xiao ◽  
Yancheng Zhang ◽  
Jie Zhou
2021 ◽  
Vol 2021 ◽  
pp. 1-12
Author(s):  
Jiansheng Zhang ◽  
Qiuyun Wang ◽  
Guiqian Xiao ◽  
Jie Zhou

To improve the service life of hot forging die, the additive manufacturing algorithm and additive manufacturing device for die remanufacturing are developed. Firstly, a compound filling algorithm in which the inner zone is filled by linear scanning and the outer contour is filled by offsetting is developed in order to solve the problems encountered in filling path planning for wire arc additive manufacturing (WAAM) like staircase effect at marginal division, degenerated edge at outer contour, programming difficulty, and so forth. Meanwhile, the attitude control algorithm of welding gun is proposed to control the angle between welding gun and welding path so as to improve the welding forming quality. Secondly, the high-temperature and low-temperature wear resistances of Fe-based and Ni-based alloy are tested. The results show that Ni-based alloy has higher high-temperature wear resistance. Finally, a disabled crankshaft hot forging die is selected for application test and the results show that, using the techniques discussed in this paper, welding materials can be saved by more than 50% and machining cost can be saved by more than 60%. In addition, the surface of automatic-repaired die is smooth without oxidation, collapse, and other defects after forging 3000 times, which is much better than that of manual-repaired die.


2021 ◽  
Author(s):  
Xiaoying Hong ◽  
Guiqian Xiao ◽  
Yancheng Zhang ◽  
Jie Zhou

Abstract In this paper, an automatic WAAM technology are proposed to realize the gradient additive remanufacturing of ultra-large hot forging dies. Firstly, a vertical additive manufacturing strategy and a normal additive manufacturing strategy are proposed to meet different additive manufacturing demands. Secondly, the basic principle of layering design of ultra-large hot forging dies is developed, and the wear resistance of Ni-based, Co-based and Fe-based alloys at room temperature and high temperature is analyzed. The Co-based alloy has the best high temperature wear resistance, which can be used on the surface of the hot forging die to strengthen the die. In order to control the forming quality of additive manufacturing, the relationship between welding parameters and weld shape was discussed, and the reverse system of welding process parameters was built. Finally, a typical aviation ultra-large hot forging die is selected as the research object. According to different stress and temperature distribution in different regions of the ultra-large hot forging die in service, materials with different properties are used in corresponding regions to improve the service life of the die, reduce the remanufacturing costs and improve the remanufacturing efficiency. The experimental results show that the service life of the hot forging die repaired by the automatic gradient function WAAM technology is significantly increased, the material is reduced by more than 50% and the production efficiency is increased by more than 50%.


2020 ◽  
Vol 109 (5-6) ◽  
pp. 1613-1623 ◽  
Author(s):  
Jiansheng Zhang ◽  
Jie Zhou ◽  
Qiuyun Wang ◽  
Guiqian Xiao ◽  
Guozheng Quan

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 474 ◽  
Author(s):  
Zixiang Li ◽  
Yinan Cui ◽  
Jie Wang ◽  
Changmeng Liu ◽  
Jiachen Wang ◽  
...  

Stellite 6 alloy has excellent wear resistance, corrosion resistance, and oxidation resistance, however the difficulties in traditional processing limit its wide application. Additive manufacturing technology that has emerged in recent years is expected to provide a new way for the processing of stellite 6 alloy. In this study, two square thin-walled stellite 6 parts were fabricated through the wire arc additive manufacturing technology. At the same time, the effect of stress relief annealing on the mechanical performance of the fabricated stellite 6 part was studied and compared with the corresponding casting part. The results indicate that the additive manufacturing stellite 6 components exhibit satisfactory quality and appearance. Moreover, the microstructure of the additive manufacturing part is much finer than that of the casting part. From the substrate to the top region of the additive manufacturing part, the morphology of the dendrites changes from columnar to equiaxed, and the hardness increases firstly and then decreases gradually. In addition, the average hardness of the additive manufacturing part is ~7–8 HRC higher than the casting part. The ultimate tensile strength and yield strength is ~150MPa higher than the casting part, while the elongation is almost the same. The stress relief annealing has no significant effect on the hardness of the AM part, but it can slightly improve the strength.


2013 ◽  
Vol 712-715 ◽  
pp. 615-618 ◽  
Author(s):  
Yong Bo Li ◽  
Jie Zheng Deng ◽  
Yang Yang ◽  
Jia He

With the development of machinery and mold manufacturing industry, there is a great significance of using composite manufacturing technology on surface hardening products to improve the quality and longevity. With the example of hot forging the automobile brake supporting frames, this paper explores to introduce hot forging die nc welding method, aiming to reduce the forging manufacturing costs and improve the reuse efficiency.


Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1415
Author(s):  
Dan Liu ◽  
Boyoung Lee ◽  
Aleksandr Babkin ◽  
Yunlong Chang

Additive manufacturing technology is a special processing technology that has developed rapidly in the past 30 years. The materials used are divided into powder and wire. Additive manufacturing technology using wire as the material has the advantages of high deposition rate, uniform composition, and high density. It has received increasingly more attention, especially for the high efficiency and rapid prototyping of large-size and complex-shaped components. Wire arc additive manufacturing has its unique advantages. The concept, connotation, and development history of arc additive manufacturing technology in foreign countries are reviewed, and the current research status of arc-based metal additive manufacturing technology is reviewed from the principles, development history, process, and practical application of arc additive manufacturing technology. It focuses on the forming system, forming material, residual stress and pores, and other defect controls of the technology, as well as the current methods of mechanical properties and process quality improvement, and the development prospects of arc additive manufacturing technology are prospected. The results show that the related research work of wire arc additive manufacturing technology is still mainly focused on the experimental research stage and has yet not gone deep into the exploration of the forming mechanism. The research work in this field should be more in-depth and systematic from the physical process of forming the molten pool system from the perspectives of stability, the organization evolution law, and performance optimization. We strive to carry out wire arc additive forming technology and theoretical research to promote the application of this technology in modern manufacturing.


2021 ◽  
Vol 723 (5) ◽  
pp. 052017
Author(s):  
V Monashkov ◽  
I Russkova ◽  
Y Logvinova ◽  
N Rumyantseva ◽  
A Uljanov

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