Abstract
A three-dimensional droplet-pool coupled model with dispersed phase (solid SiC particles) was developed to simulate TIG-assisted droplet deposition manufacturing (DDM) of silicon carbide particle-reinforced aluminum matrix composites (AMCs), which was employed to calculate the surface morphology of the deposited layer, the thermal-flow fields and the distribution state of reinforcing particles in the molten pool. The cross-section profile of a single-track SiC-reinforced AMC deposit and the distribution state of reinforcement were examined and compared with the findings predicted by simulation, a good agreement was achieved. It is found that the impacting droplet including the SiC reinforcement creates an obvious crater within the molten pool. The viscous damping and simultaneous solidification are the main factors that dissipate the kinetic energy of the droplet. In addition, we discuss quantitatively how impact-induced thermodynamic within molten pool can change the migration behavior and distribution state of SiC reinforcement. The non-homogeneous distribution of the particles can be attributed to the thermocapillary micro-convection and the velocity difference in the spreading and recoiling stages.
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