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2222材料工程  2022, Vol. 50 Issue (1): 1-14    DOI: 10.11868/j.issn.1001-4381.2021.000741
  搅拌摩擦焊接专栏 本期目录 | 过刊浏览 | 高级检索 |
基于搅拌摩擦的金属固相增材制造研究进展
石磊1,2,*(), 李阳1, 肖亦辰1, 武传松1, 刘会杰2
1 山东大学 材料液固结构演变与加工教育部重点实验室, 济南 250061
2 哈尔滨工业大学 先进焊接与连接国家重点实验室, 哈尔滨 150001
Research progress of metal solid phase additive manufacturing based on friction stir
Lei SHI1,2,*(), Yang LI1, Yichen XIAO1, Chuansong WU1, Huijie LIU2
1 Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University, Jinan 250061, China
2 State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China
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摘要 

基于搅拌摩擦的固相增材制造是大型轻质合金构件成形制造的新技术, 已成为国内外先进成形制造领域研究的热点之一。本文对目前国内外基于搅拌摩擦的金属固相增材制造技术及其相关工艺机理的研究现状进行了分析和总结。常见的基于搅拌摩擦的固相增材制造技术可分为三类: 基于搅拌摩擦搭接焊原理, 使板材逐层堆积, 从而获得增材构件的搅拌摩擦增材制造(friction stir additive manufacturing, FSAM)技术; 采用中空搅拌头, 通过添加剂(粉末或丝材)进行固相搅拌摩擦沉积的增材制造(additive friction stir deposition, AFSD)技术; 采用消耗型棒材, 通过棒材的摩擦表面处理, 形成增材层的摩擦表面沉积增材制造(friction surfacing deposition additive manufacturing, FSD-AM)技术。重点分析了金属材料基于搅拌摩擦的固相增材制造技术的国内外研究与应用现状, 对比了三类基于搅拌摩擦的固相增材制造技术的特征及其工艺优缺点。最后指出增材工艺机理、形性协同控制、外场辅助工艺改型、新材料应用和人工智能优化是基于搅拌摩擦的固相增材制造技术未来研究的重点方向。
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石磊
李阳
肖亦辰
武传松
刘会杰
关键词 ： 增材制造,  固相增材制造,  搅拌摩擦增材制造,  搅拌摩擦沉积增材制造,  摩擦表面沉积增材制造    
Abstract：

Solid phase additive manufacturing based on friction stir is a new technology for manufacturing of large lightweight alloy components, which has become one of the hot research topics in advanced manufacturing field at home and abroad.The research status of metal solid phase additive manufacturing technology based on friction stir and related process mechanism were analyzed and summarized. The solid phase additive manufacturing technology based on friction stir can be divided into three categories.One is friction stir additive manufacturing(FSAM), which is based on the principle of friction stir lap welding, the plates are stacked layer by layer. Another is additive friction stir deposition(AFSD) technology, which usually uses a hollow tool to conduct AFSD by additive powder or wire through the hollow.The third one is friction surfacing deposition additive manufacturing (FSD-AM) technology, which is based on the principle of friction surfacing by using a rotating consumable bar to deposit materials to form the designed components. The research and application status of solid phase additive manufacturing technology of metal materials based on friction stir were analyzed, and the characteristics, advantages and disadvantages of three kinds of solid phase additive manufacturing technology based on friction stir were compared.Finally, the future research direction of solid phase additive manufacturing technology based on friction stir was proposed, including revealing their process mechanism, integrated controlling of the formation and property of the AM components, modifying the process assisted with second energy, application of new materials and optimization with artificial intelligence, etc.
Key words： additive manufacturing    solid phase additive manufacturing    friction stir additive manufacturing    additive friction stir deposition    friction surfacing deposition additive manufacturing
收稿日期: 2021-08-05      出版日期: 2022-01-19
中图分类号:  TG44  
基金资助:国家自然科学基金项目(51905309);国家自然科学基金项目(52035005);哈尔滨工业大学先进焊接与连接国家重点实验室开放课题(AWJ-21M16)
通讯作者: 石磊     E-mail: lei.shi@sdu.edu.cn
作者简介: 石磊(1987—)，男，教授，博士生导师，从事搅拌摩擦焊接与增材制造研究，联系地址：山东省济南市经十路17923号山东大学材料科学与工程学院焊接研究所(250061)，E-mail: lei.shi@sdu.edu.cn
引用本文:   
石磊, 李阳, 肖亦辰, 武传松, 刘会杰. 基于搅拌摩擦的金属固相增材制造研究进展[J]. 材料工程, 2022, 50(1): 1-14.
Lei SHI, Yang LI, Yichen XIAO, Chuansong WU, Huijie LIU. Research progress of metal solid phase additive manufacturing based on friction stir. Journal of Materials Engineering, 2022, 50(1): 1-14.
链接本文:  
http://jme.biam.ac.cn/CN/10.11868/j.issn.1001-4381.2021.000741      或      http://jme.biam.ac.cn/CN/Y2022/V50/I1/1
Fig.1  典型金属增材制造技术
AM technology Feature Benefit Limitation
Solid-phase AM No-melting of the base materials and the feeding material, without flux or shielding gas, no fumes Green manufacturing technologies, eliminate the majority of fusion-based defects, lower energy consumption, broad material range, can easily fabricate multi-material and functionally graded materials, higher lateral strength as compared to fusion-based AM, high deposition rate, without flux or shielding gas, low distortion Lower dimensional accuracy, necessary of materials subtractive process, difficulty in utilizing in complex structure
Fusion-based AM Melting of the base and filling materials, with flux or shielding gas or under vacuum conditions Flexibility, suitable for small, accurate and intricate parts when using laser as heating source, lower costs for small-lot manufacturing Porosity, cracking, delamination and loss of alloying elements
Table 1  金属固相增材制造技术与熔融增材制造技术的特征比较[6]
Fig.2  搅拌摩擦焊接原理 (a)对接焊；(b)搭接焊
Fig.3  三类基于搅拌摩擦的固相增材制造工艺原理[9]
(a)搅拌摩擦增材制造技术；(b)搅拌摩擦沉积增材制造技术；(c)摩擦表面沉积增材制造技术
Technique Working principle Application material
FSAM A non-consumable tool is inserted into the stack of overlapping plates and friction stir lap welding is carried out along the defined direction with optimum process parameters. These steps are then repeated up to the desired build layer Aluminum alloys, magnesium alloys, steel, Inconel alloy, etc
AFSD A tool with inside hole is used during AFSD. Material addition in the form of metal powder or a solid rod takes place from the inside hole of a non-consumable tool. The material from the inside hole is deposited over the substrate or pre-deposited layer Aluminum alloys, magnesium alloys, metal matrix composite, etc
FSD-AM A consumable tool is utilized for depositing surface coating layers by metallurgical bonding via frictional heating. Material deposited from the consumable rod over the desired area takes place as the tool traverse Stainless steel, aluminum alloys, etc
Table 2  三类基于搅拌摩擦的固相增材制造工艺原理与典型应用材料情况[13]
Fig.4  搅拌摩擦增材制造工艺过程图[19]
Fig.5  基于搅拌摩擦的固相增材制造与熔融增材制造的对比[10, 17]
AM technology based on friction stir Feed material Friction stir tool Benefit Limitation
FSAM Plate Conventional or stationary shoulder FSW tool Broadened alloy space, no requirement of filler, engineering microstructure possible Requires special fixtures, susceptible to defects like hooking, low manufacturing efficiency and necessary of material substrate process
AFSD Wire，powder，etc Tool with inside hole Purely additive in nature, both powders and metal rods can be used as initial material, good lateral strength, high deposition rate Complex design of tool, dependence on machine variables
FSD-AM Bar Consumable bar Excellent tensile strength, no requirement of filler, high deposition rate, high layer thickness Unbonded regions at boundaries, reduced mass transfer efficiency
Table 3  三类基于搅拌摩擦的固相增材制造工艺的特征对比
Fig.6  基于搅拌摩擦的固相增材制造的典型构件及其潜在应用领域[6, 17, 25, 49]
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