航空发动机叶片电弧熔丝增材制造的熔池演化建模与验证

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Abstract： In conventional wire arc additive manufacturing，the work piece undergoes repeated heating and rapid cooling，along with unsteady material deposition.These conditionsoften lead to internal defects and high residual stressresulting in unstable mechanical performance.Unlike traditional trial-and-error methods，numerical simulation enables the modeling of the deposition process，allowing for detailed characterization of melt pool formation， flow behavior，and layer morphology when combined with actual process parameters. First，a coupled thermo-mas-fluid-solid multi-physics model was developed to simulate the single-track，multi-layer （68 layers） deposition processof 316L stainless steel used inaerospace engine blades.Next，the flow paterns within the melt pooland the morphologyof the deposited layers were further analyzed.Finally，the simulationresults were validated usingthree-dimensional geometric data obtained from TIG-fabricated blade specimens.The predicted and measuredgeometries showed strong agreement， with a maximum deviation of less than 5% ， confirming the model's accuracy and reliability in predicting melt pool dynamics and interlayer morphology.

Keywords： CFD;additive manufacturing; deposition; curved blade; molten pool flow

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作为发动机中的核心部件，航空发动机叶片常因受到高交变应力而引发疲劳，导致裂纹产生及扩展。（剩余11052字）