多功能梯度零件电-磁场柔性复合熔积控制直接成形

Aiming at meeting the nationally critical demand for direct rapid manufacturing of the new multi-functional parts with high-performance like aero engine parts and solving the difficult problem in the frontier of metal direct manufacturing- the high-efficient shaping of multi-functionally graded material (MFGM) components with concurrent control of formability and performance, a new direct deposition shaping method with flexible control of multi-feature electromagnetic field is proposed and studied. The method is based on the flexible combination of high frequency, static magnetic and the deposition electrical field, along with controlling the sequence and position and electromagnetic parameters. Not only the productivity is promoted by avoiding the problems such as flowing-down, deformation and crack, but also the grain morphology is controllable and interface bond is intensified, thereby efficiently create MFGM component with ultimate performance. The project will explore the evolution principle of stress and microstructure in the supernormal shaping process under the effect of the combined electrical-magnetic and mass transfer-kinematics field, and reveal the mechanism for concurrently controlling formability and performance of MFGM component under the combined field using macroscopic and microscopic multi-scale simulations and experiments. The project will develop an electromagnetically controlled efficient direct shaping technology prototyping and an intelligent method of concurrently designing microstructure, geometrical topology and process parameters with comprehensive considerations of service performance, formability and productivity. This project enhances the development of the science theory and the intelligent short process manufacturing with special physical fields, and provides innovative core technology foundation support for high-quality, efficient and low-cost shaping of key component in strategic industries.

针对航空发动机、核电等多功能高性能金属零件快速制造的国家重大需求，挑战金属零件直接成形技术前沿难题-梯度组织多功能复合（MFGM）高性能零件的成形性与性能并行控制高效成形，提出并研究MFGM零件多特性电磁场柔性复合控制熔积直接成形新方法。即将外加高频或恒稳磁场与熔积电场柔性复合，并控制复合时序和位向及电磁参数，既可抑制变形和开裂，提高成形效率，又可自由调控组织形态空间分布，并强化界面结合，从而高效创制极限性能MFGM零件。探索电-磁复合场与传质-运动场耦合作用的超常态成形过程热应力与组织演变规律，用宏细观多尺度模拟与实验研究揭示复合场制备MFGM零件形性并行控制机理，建立MFGM零件电磁控制高效直接成形技术原型，发展特殊物理场短流程制造科学理论，为战略产业关键零部件的高性能高效低成本制造提供自主创新核心技术基础支持。

本项目针对航空发动机、核电等多功能高性能金属零件快速制造的国家重大需求，以及高性能零件3D打印技术实用化中所遇到的瓶颈--性能与成形性难以控制的问题，向金属零件直接成形技术前沿难题--梯度组织多功能复合（MFGM）高性能零件的成形性与性能并行控制、高效成形进行了挑战。提出并研究了MFGM零件多特性电磁场柔性复合控制熔积直接成形新方法。在国内外率先提出时空可控电磁场与随动半固态微型轧制复合增材制造高性能多功能复杂梯度零件的新方法。.主要研究内容为：.（1）电磁柔性复合熔积成形MFGM制件的宏细微观机理研究.（2）电磁柔性复合熔积成形MFGM制件的成形性与形状质量控制规律研究.（3）电磁柔性复合熔积成形MFGM制件的组织形成及控制规律的研究.（4）MFGM零件电磁柔性复合熔积成形的试验研究.将外加高频或恒稳磁场与熔积电场柔性复合，并控制复合时序和位向及电磁参数，既可抑制变形和开裂，提高成形效率，又可自由调控组织形态空间分布，并强化界面结合，从而高效创制极限性能MFGM零件。针对外加电磁场下的电弧熔积成形，建立了电磁--热--应力--流体多场耦合的系统仿真框架，实现了外加电磁场下的电弧熔积成形过程的高效有限元电磁计算。.探索了电-磁复合场与传质-运动场耦合作用的超常态成形过程热应力与组织演变规律，利用外加电磁热减小零件残余应力和变形，提出了外加电磁热的仿真策略，用宏细观多尺度模拟与实验研究揭示复合场制备MFGM零件形性并行控制机理，发现了外加纵向磁场驱动了强烈的熔池旋转搅拌流动。借助仿真工具和有限元电磁分析，实现了外加电磁场对晶粒大小的控制（细化或粗化），以及对熔池流场影响的预测。.通过本项目的研究，建立了MFGM零件电磁控制高效直接成形技术，以及电磁微铸轧无模直接制造的创新技术装备原型，实现了新型高性能FGM零件形状与组织的并行智能化创制与调控，发展出特殊物理场短流程制造科学理论，为战略产业关键零件的高性能高效低成本制造提供自主创新核心技术基础支持。