增材制造技术发展和在先进轨道交通装备中的应用展望

杨冰; 廖贞; 吴圣川; 肖守讷; 阳光武; 朱涛; 王明猛; 邓永权

doi:10.19818/j.cnki.1671-1637.2021.01.006

增材制造技术发展和在先进轨道交通装备中的应用展望

doi: 10.19818/j.cnki.1671-1637.2021.01.006

西南交通大学牵引动力国家重点实验室，四川成都 610031

基金项目:

国家自然科学基金 51675446

国家自然科学基金 U2032121

详细信息

作者简介:
杨冰(1979-), 男, 湖南衡阳人, 西南交通大学研究员, 工学博士, 从事车辆结构强度与可靠性研究

中图分类号: U270.4
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出版历程
- 收稿日期: 2020-09-29
- 刊出日期: 2021-08-27

Development of additive manufacturing technology and its application prospect in advanced rail transit equipment

State Key Laboratory of Traction Power, Southwest Jiaotong University, Chengdu 610031, Sichuan, China

Funds:

National Natural Science Foundation of China 51675446

National Natural Science Foundation of China U2032121

More Information

Author Bio:
YANG Bing(1979-), male, professor, PhD, yb@swjtu.edu.cn

摘要

摘要: 从增材制造技术的应用现状出发，概述了几种增材制造技术的特点和应用范围；介绍了典型的金属增材制造最新研究进展；考虑现有增材制件存在的固有缺陷、残余应力和裂纹等问题，总结了能有效改善成形增材制件质量的后处理工序；梳理了增材制件疲劳性能的影响因素，重点阐述了缺陷与增材制件疲劳损伤的关联性；探讨了增材制造技术广泛应用所涉及的关键技术；系统总结了金属增材制造技术在国内外轨道交通装备领域的应用现状。研究结果表明：由于热源和工艺参数不同，增材制造技术制备材料的组织特性和力学性能存在差异；增材制造的钛合金、铝合金以及其他前沿金属材料在轨道交通装备领域具有较好的应用前景；合理的后处理工艺可以有效控制缺陷的形成，消除残余应力，减少微裂纹；缺陷作为制约增材制造技术在制造行业应用的关键因素，研究其分布规律和探究其与疲劳性能的关系，对增材制件的疲劳性能评估有重要作用；从材料规范、成形精度、质量控制、生产效率、生产链以及无损检测技术等方面，综合增强增材制造关键技术自主创新性研发，有助于提升中国制造行业在国际上的竞争力；增材制造技术受到轨道交通行业的重视，并开始应用这种新型技术成形了金属结构件，但该技术的成熟应用仍面临许多问题，需要国内外学者进一步开展深入研究。
- 车辆工程 /
- 增材制造 /
- 材料特性 /
- 后处理工序 /
- 疲劳性能 /
- 内部缺陷
Abstract: Based on the application status of additive manufacturing technology, the characteristics and application ranges of several additive manufacturing technologies were summarized. The latest research progress of typical metal additive manufacturing was introduced. Considering the inherent defects, residual stresses and cracks of the existing additive manufactured parts, the post processes which can effectively improve the quality of the formed additive manufactured parts were summarized. The influencing factors of fatigue performance of additive manufactured parts were sorted out, and the correlation between defect and fatigue damage of additive manufactured parts was emphasized. The key technologies involved in the wide application of additive manufacturing technology were discussed. The application status of metal additive manufacturing technology in the field of rail transit equipment at home and abroad was systematically summarized. Analysis result shows that the texture characteristic and mechanical properties of materials prepared by the additive manufacturing technology are different due to different heat sources and process parameters. Additive manufacturing titanium alloy, aluminum alloy and other advanced metal materials have a good application prospect in the field of rail transit equipment. Reasonable post processes can effectively control the formation of defects, eliminate residual stresses and reduce micro cracks. Defects are the key factors to restrict the application of additive manufacturing technology in the manufacturing industry, it is important to study the distribution law of defects and explore the relationship between defects and fatigue performance for the evaluation of fatigue performance of additive manufactured parts. From the aspects of material specification, forming accuracy, quality control, production efficiency, production chain and nondestructive testing technology, comprehensively improving the independent and innovative research and development of key technologies of additive manufacturing is conducive to enhancing the competitiveness of Chinese manufacturing industry in the world. The additive manufacturing technology has attracted the attention of rail transit industry, and begin to adopt this new technology to form metal structural parts, but the wide application of this technology still faces many problems, which need to carry out in-depth research by the scholars at home and abroad. 2 tabs, 21 figs, 111 refs.
- vehicle engineering /
- additive manufacturing /
- material property /
- post process /
- fatigue performance /
- internal defect

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图 1 SLS工艺原理

Figure 1. Principle of SLS process

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图 2 SLM工艺原理

Figure 2. Principle of SLM process

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图 3 EBM工艺原理

Figure 3. Principle of EBM process

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图 4 LENS工艺原理

Figure 4. Principle of LENS process

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图 5 WAAM工艺原理

Figure 5. Principle of WAAM process

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图 6 2017~2020年3D打印材料种类和数量变化

Figure 6. Changes of type and quantity of 3D printing materials in 2017-2020

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图 7 SLM成形钛合金内部典型缺陷

Figure 7. Typical internal defects of titanium alloy formed by SLM

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图 8 SLM成形铝合金常见缺陷

Figure 8. Common defects of aluminium alloy fabricated by SLM

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图 9 3D打印的A320飞机隔断结构

Figure 9. 3D printed A320 aircraft partition structure

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图 10 3D打印A20X航空航天部件

Figure 10. 3D printed A20X aerospace component

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图 11 几种不同的轧制方法

Figure 11. Several different rolling methods

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图 12 不同工艺制备的Ti-6Al-4V合金疲劳曲线

Figure 12. Fatigue curves of Ti-6Al-4V alloy fabricated by different processing techniques

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图 13 疲劳试验结果对比

Figure 13. Comparison of fatigue test results

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图 14 原位疲劳试验机

Figure 14. In situ fatigue testing machine

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图 15 同步辐射X射线断层扫描重建缺陷三维形貌

Figure 15. 3D reconstruction of defects by synchrotron radiation X-ray tomography

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图 16 无损检测技术在制造行业的应用实例

Figure 16. Application examples of nondestructive testing technology in manufacturing industry

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图 17 激光熔覆修复铁路车轴

Figure 17. Repair of railway axle by laser cladding

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图 18 3D打印制动悬挂连杆

Figure 18. 3D printed brake suspension link

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图 19 传统成形传动杆和SLM成形传动杆

Figure 19. Traditional technique and SLM technique processed transmission bars

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图 20 3D打印轨道交通设备零部件

Figure 20. 3D printed parts for rail transit equipment

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图 21 用于轨道交通轻量化装备的3D打印零部件

Figure 21. 3D printed parts for rail transit lightweight equipment

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表 1 不同热处理条件下Ti-6Al-4V合金的力学性能

Table 1. Mechanical properties of Ti-6Al-4V alloy under different heat treatment conditions

热处理条件	抗拉极限强度/MPa	0.2%屈服强度/MPa	断裂延伸率/%
不处理	1 080	1 008	1.6
800 ℃	1 040	962	5.0
1 050 ℃	945	798	11.6
HIP	1 005	912	8.3

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表 2 主要缺陷类型及其来源

Table 2. Major types of defects and their sources

缺陷类型	缺陷特征	缺陷来源
未熔合	未烧结区域、层与层之间的未熔合	能量不足
未熔化粉末	粉末熔化不完全	能量不足
气孔	滞留气体	能量过饱和
成球现象	材料不连续	固体颗粒缺乏湿润性
氧化物颗粒		氧含量
α相		反复加热和冷却过程
水珠状聚集		熔体凝固为滴液线，而不是连续的层
表面粗糙	部分熔化的粉末颗粒	逐层粉末原料

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