基于CFD模型的电弧焊接增材制造过程热物理分析及焊道形态研究OA

In wire arc additive manufacturing,droplet transfer and molten pool dynamics are critical factors influencing weld bead morphology.This study develops a three-dimensional transient computational fluid dynamics model that incorporates mass,energy,momentum,and volume of fluid equations.The model captures droplet transfer,gravity,molten pool flow,and solid-liquid phase transitions.Using this framework,we quantitatively analyze the effects of welding speed,droplet tempera-ture,and welding position on the morphology of single-layer and multi-layer weld beads under the TIG process.The results indicate that increasing the welding speed reduces the molten pool height by 59.14%(from 8 mm/s to 28 mm/s)and intensi-fies the instability of molten pool flow at higher speeds.A higher droplet temperature corresponds to increased heat input per unit time,resulting in a larger molten pool volume.The molten pool height increases by 19.86%,while its width expands by 11.64%(from 2 300 K to 3 100 K).Changes in welding position,which alter the gravitational direction,significantly affect molten pool flow patterns.During multi-layer deposition,the weld bead morphology exhibits a lower profile at the arc extinc-tion point and a higher profile at the arc initiation point.The accuracy of the model is validated by comparing the simulated multi-layer weld bead morphology in flat,horizontal,and overhead welding positions with experimental data.