Abstract
A transient three-dimensional (3D) numerical model was established to illustrate the heat transfer, fluid flow and particle migration behaviors in the molten pool during TIG-assisted droplet deposition manufacturing (DDM) of SiC particle-reinforced aluminum matrix composites (AMCs). The effect of temperature-dependent physical properties and the interaction between the SiC reinforcement and the liquid metal matrix were considered. A double-ellipsoidal volumetric heat source model was adopted to simulate the energy interactions between the pulse square-wave variable polarity TIG welding arc and the moving substrate. Free surface fluctuations of molten pool due to arc force and sequential droplet impact are calculated with volume of fluid (VOF) method in a fixed Eulerian structured mesh. The numerical model, capable of capturing the impact, simultaneous spread, and phase change of the droplets as well as the motion trajectory and terminate distribution state of the reinforcement particles, is key tool to understand the formation mechanism of the TIG-assisted DDM of SiC particle-reinforced AMCs. The numerical model was validated by the metallographic observations, and the calculated particle distribution and solidification morphology of deposited layer agree well with the experimental measurements.
Highlights
Compared to unreinforced metal matrix, ceramic-reinforced metal matrix composites (MMCs) can be utilized in extreme working conditions and some high-end engineering industries due to their higher mechanical, thermal, and fatigue properties at elevated temperatures [1]
Reinforced aluminum matrix composites (AMCs) have the improved mechanical properties, such as the tensile strength [7], the yield strength [8], and the wear resistance [9]. It is difficult for the abovementioned preparation methods of particle-reinforced AMCs to fabricate complex-shaped components [10], and, they have problems of high cost and energy consumptions
SiC particles with different size and volume fraction were employed to analyze the behaviors of the composite, demonstrating that cracking occurs during the direct metal laser sintering (DMLS) of these composites
Summary
Compared to unreinforced metal matrix, ceramic-reinforced metal matrix composites (MMCs) can be utilized in extreme working conditions and some high-end engineering industries (i.e., automotive, aerospace, etc.) due to their higher mechanical, thermal, and fatigue properties at elevated temperatures [1]. Reinforced AMCs have the improved mechanical properties, such as the tensile strength [7], the yield strength [8], and the wear resistance [9] It is difficult for the abovementioned preparation methods of particle-reinforced AMCs to fabricate complex-shaped components [10], and, they have problems of high cost and energy consumptions. A 3D numerical simulation model based on finite volume method (FVM) was proposed to understand and analyze the molten pool dynamics and particle-melt interactions within the molten pool during the TIG-assisted DDM of SiC particle-reinforced AMCs. The resultant distribution state of SiC particles in the solidified aluminum matrix was experimentally examined, which is in a good agreement with the results calculated by simulation
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