Abstract

Numerical simulations combined with electron beam melting were adopted to study the effect of the thickness of the preset coating on the quality of electron beam melting and forming of aluminum alloys. The research was carried out using ANSYS19.0 finite element analysis software to perform the numerical simulation of the temperature field and stress field during the process of electron beam melting of the Ni60 coating on 6061 aluminum alloy. The results show that the thicker the preset coating, the higher the surface temperature and the greater the melting depth and width of the melt pool, but the smaller the substrate melting depth, and the highest surface temperature obtained was 2536.05 °C. When the coating thickness reached 1.5 mm, the substrate essentially showed no change; otherwise, the thicker the preset coating, the greater the residual stress, and the maximum residual stress on the coating surface along the scanning direction appeared at the position near the boundary. Moreover, the maximum residual stress along the depth direction occurred at the interface. The electron beam cladding experiments showed that the 0.5 mm thickness of the coating resulted in a cracking phenomenon at the interface with the substrate, and the surface of the molten layer had more defects such as pores and pits; the 1 mm thickness of the coating had a good metallurgical bond with the substrate, and the surface of the molten layer was dense and flat; the 1.5 mm thickness of the aluminum alloy substrate did not melt, and the surface of the molten layer had more cracks. The numerical simulation was essentially consistent with the electron beam cladding experiment, and the forming quality was better when the preset coating thickness was 1 mm.

Highlights

  • IntroductionAluminum alloys are the premium material for aerospace and automotive manufacturing due to their low density and high strength ratio

  • Publisher’s Note: MDPI stays neutralAluminum alloys are the premium material for aerospace and automotive manufacturing due to their low density and high strength ratio

  • We simulate the tempowder coated by an electron beam of aluminum alloy to verify the effect of the preset perature and stress fields of Ni60 alloy powder coated by an electron beam of aluminum coating thickness on the quality of molten clad forming; namely, a proper coating thickness alloy to verify the effect of the preset coating thickness on the quality of molten clad can improve the forming quality of the molten clad layer, reduce the generation of cracks forming; namely, a proper coating thickness can improve the forming quality of the and increase the bonding strength of the molten clad layer

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Summary

Introduction

Aluminum alloys are the premium material for aerospace and automotive manufacturing due to their low density and high strength ratio. The melting point, hardness and corrosion resistance of aluminum alloys are low compared to many alloy materials, which limits their application in industry [1]. There is a large amount of research on the surface modification of aluminum alloys at home and abroad [2–6], such as chemical conversion film, electroplating, micro-arc oxidation, laser melting and electron beam melting, etc.

Schematic
Temperature Field Finite Element Simulation
Thermal and Physical Parameters of the Material
Establishment of Finite Element Model
Selection
Simulation of Electron
Temperature
Model Building
Applying
Mechanical
Influence
Experimental Verification of Electron Beam Cladding
Findings
Conclusions
Full Text
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