Research on dimensional instability control of aluminum alloy thin-walled components based on droplet + arc additive manufacturing

Abstract

Although droplet + arc additive manufacturing technology has significant advantages in the efficiency of producing metal components but faces challenges in achieving dimensional accuracy during forming processes. This article addresses these challenges through a structured approach. To this end, a mathematical model is developed to predict the flight distance of molten droplets. Based on this model, displacement compensation is designed to ensure precise initial positioning during single-layer deposition. Secondly, thermal accumulation characteristics within the forming system during layer-by-layer deposition are analyzed. This involves integrating process parameters with temperature monitoring data between deposition layers to establish an energy balance relationship. Thirdly, secondary deposition is conducted on a 10-layer thin-walled component to explore the relationship between arc energy density and deposition layer size under conditions of two-dimensional heat dissipation. The results highlight the importance of controlling arc energy density in droplet + arc additive manufacturing to customize thin-walled dimensions, optimize thermal accumulation effects, and enhance the stability of sample formation.