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An angle-driven parameter control model for corner paths in the DED-arc process of nickel aluminum bronze alloy

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Abstract

The directed energy deposition-arc (DED-arc) process is gaining popularity for cost-effective production of large parts, especially in the marine industry. However, precise shaping control, especially for parts with sharp corners, has been challenging. Nickel aluminum bronze (NAB) alloy, widely used in the marine field, is an expensive material, making it crucial to improve its forming accuracy. To tackle this challenge, the Angle-Driven Parameter Control Model (APCM) has been introduced. This model is designed to enhance corner paths in the DED-arc process for NAB alloy. By adjusting the travel speed, the APCM aims to reduce height errors at corners. To validate the effectiveness of the APCM, single bead depositions and a multi-layer thin-wall component with seven different angles (10°, 20°, 30°, 45°, 60°, 75°, and 90°) were tested. Results indicate that the APCM has a more significant optimization effect at smaller angles. For angles above 60°, relatively small height deviations can be achieved without parameter control. For the 15-layer thin-wall component, the APCM control reduced the height deviation at the 10° angle from 7.72 to 2.09 mm. Therefore, the proposed APCM is ideal for corner paths in the DED-arc process of NAB alloy.

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Funding

This work is supported by “Deep Blue Project” Fund of Shanghai Jiao Tong University (No. WH410260401/027), the Fundamental Research Funds for the Central Universities and Institute of Marine Equipment, National Natural Science Foundation of China (NSFC, No. U1937601), and Shanghai Rising-Star Program of Science and Technology Commission of Shanghai Municipality (STCSM, No. 23QA1404700).

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Authors and Affiliations

  1. Shanghai Key Laboratory of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Jiacheng Huang, Fang Li, Chen Shen, Yuelong Zhang & Xueming Hua

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  1. Jiacheng Huang
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  2. Fang Li
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  3. Chen Shen
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  4. Yuelong Zhang
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Jiacheng Huang. The first draft of the manuscript was written by Jiacheng Huang, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Fang Li.

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Huang, J., Li, F., Shen, C. et al. An angle-driven parameter control model for corner paths in the DED-arc process of nickel aluminum bronze alloy. Int J Adv Manuf Technol 130, 5285–5298 (2024). https://doi.org/10.1007/s00170-024-12963-8

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