激光熔覆tiha复合材料加工过程热—机械耦合研究与数值模拟-thermo-mechanical coupling research and numerical simulation of laser cladding tiha composite during processing.docx

摘要本文对 Ti/HA 熔覆过程进行了热-机械耦合分析，实现了对激光功率密度、送粉 速度、扫描速度以及搭接率工艺参数优化，对构件热应力及残余应力分布进行分析， 预测了可能开裂区域以及开裂方向。同时，对减小残余应力方法进行了对比讨论。假设熔覆层截面为椭圆，其体积只与送粉速度有关，通过尺寸修改以及迭代算 法，求解出熔覆层真实形状。基于单道激光熔覆有限元模拟，求解出熔覆层宽度、 高度、熔池深度和构件最高温度，实现对激光功率密度、送粉速度和扫描速度的优 化选择。在模型中考虑了热流密度、对流、辐射、绝热等边界条件，同时也考虑了 陶瓷材料高温分解，Ti 金属相变潜热等因素对温度场的影响，通过与实验测量结果 的对比，验证了数值模型的合理性。基于多道熔覆有限元模拟，对激光熔覆搭接率工艺参数进行了选优。以瞬态温 度分布为基础，结合数值计算软件，求解出熔池界面。通过对熔池界面光滑性以及 与基体搭接情况的研究，实现多种搭接率的选优，计算结果和实验结果吻合。基于热-机械耦合有限元分析，对构件热应力以及残余应力进行了分析，预测了 可能开裂区域以及开裂方向。采用预热法和温差拉伸法，实现了降低残余应力的目 的。为了深入了解熔覆过程中热应力分布以及残余应力的形成，通过建立理想简化 模型，对熔覆层与基体材料特性不匹配因素进行研究讨论。结合构件残余应力分布 情况，预测熔覆层有可能垂直于扫描方向开裂，以及熔覆层与基体有可能界面开裂。 最后，通过预热法和温差拉伸法的模拟计算，提出几种可行的减小残余应力方法， 从加工工艺方面，讨论降低残余应力的可行性和理想的 Ti/HA 熔覆效果。关键词：激光熔覆，Ti/HA，热-机械耦合分析，温度场，残余应力AbstractIn this dissertation, thermo- mechanical finite element analys is on laser cladding of Ti/HA is presented. Optimum process parameters are obtained, including scanning velocity, powder flow velocity, laser intensity, overlapping rate. Based on temperature and residual field analysis, cracking region and direction are predicted. Furthermore, a number of feasible approaches are proposed for the purpose of eliminating or depressing residual stress. The valid ity has been confirmed sufficient ly in simulation.The time dependent temperature field caused by moving Gauss distributing heat source are numerically calculated for the laser cladding of single-path and multi-paths. In 3D model, material failure of HA, the temperature dependent material properties, enthalpy of material and various boundary conditions including radiatio n, convection and density of heat flow rate are taken into account. Based on hypothesis that the cross section of coat is half-ellipse and the temperature of coat boundary matches well with melting point, the real coat profile is obtained by dimension modifying and iterative algorithm, Using Hierarchical Parameterized Finite Element Approach, optimum process parameters are obtained, which include laser intensity, scanning velocity and powd