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Research on gradient additive remanufacturing of ultra-large hot forging die based on automatic wire arc additive manufacturing technology

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Abstract

In this paper, an automatic WAAM technology is proposed to realize the gradient additive remanufacturing of ultra-large hot forging dies. Firstly, a vertical additive manufacturing strategy and a normal additive manufacturing strategy are proposed to meet different additive manufacturing demands. Secondly, the basic principle of layering design of ultra-large hot forging dies is developed, and the wear resistance of Ni-based, Co-based, and Fe-based alloys at room temperature and high temperature is analyzed. The Co-based alloy has the best high-temperature wear resistance, which can be used on the surface of the hot forging die to strengthen the die. In order to control the forming quality of additive manufacturing, the relationship between welding parameters and weld shape was discussed, and the reverse system of welding process parameters was built. Finally, a typical aviation ultra-large hot forging die is selected as the research object. According to different stress and temperature distribution in different regions of the ultra-large hot forging die in service, materials with different properties are used in corresponding regions to improve the service life of the die, reduce the remanufacturing costs, and improve the remanufacturing efficiency. The experimental results show that the service life of the hot forging dies repaired by the automatic gradient function WAAM technology is significantly increased, the material is reduced by more than 50%, and the production efficiency is increased by more than 50%.

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Availability of data and materials

All data generated or analyzed during this study are included in this published article.

Funding

This research is supported by the National Key Research and Development Program of China (No. 2018YFB1106504). This research is supported also by Postdoctoral Science Foundation of Chongqing Natural Science Foundation (No. cstc2020jcyj-bshX0006).

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Authors and Affiliations

  1. School of Materials Science and Engineering, Chongqing University, Chongqing, 400044, China

    Xiaoying Hong & Jie Zhou

  2. Sichuan Vocational College of Information Technology, Guangyuan, 628017, China

    Xiaoying Hong

  3. Chongqing Forgestamp Inteligent Equipment Co., Ltd, Chongqing, 400000, China

    Guiqian Xiao & Yancheng Zhang

Authors
  1. Xiaoying Hong
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  2. Guiqian Xiao
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  3. Yancheng Zhang
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  4. Jie Zhou
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Contributions

Xiaoying Hong put forward the relevant algorithm and ideas, and wrote the article. Guiqian Xiao wrote the software and developed the hardware and carried out experiments. Yancheng Zhang did the welding process parameter experiment. Jie Zhou guided and reviewed the whole process.

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Correspondence to Jie Zhou.

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Hong, X., Xiao, G., Zhang, Y. et al. Research on gradient additive remanufacturing of ultra-large hot forging die based on automatic wire arc additive manufacturing technology. Int J Adv Manuf Technol 116, 2243–2254 (2021). https://doi.org/10.1007/s00170-021-07424-5

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  • DOI: https://doi.org/10.1007/s00170-021-07424-5

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