采用Simufact Welding软件建立电弧增材制造GH4169镍基高温合金的有限元模型,对该模型进行了试验验证,模拟分析了不同沉积路径(单向沉积、往复沉积)和不同层间冷却时间(0,60,120 s)下多层单道成形过程中的热力场及变形量。结果表明:模拟得到电弧增材制造过程中的热循环曲线和残余应力与试验结果相吻合,相对误差分别小于9%和3%,验证了该模型的准确性;与单向沉积路径相比,往复沉积路径可以改善成形件热分布和应力场分布的均匀性,应力场和热积累的影响范围较小,温度和残余应力较低,变形对称性较好;随着层间冷却时间的延长,热积累、残余应力和变形量均降低,但降低幅度逐渐减小。采用往复沉积路径且层间冷却60 s时,电弧增材制造GH4169镍基高温合金的成形质量较好。

The finite element model of arc additive manufactured GH4169 nickel-based superalloy was established by Simufact Welding software, and the model was verified by tests. The thermodynamic field and deformation during multilayer single-pass forming under different deposition paths (unidirectional deposition, reciprocating deposition) and different interlayer cooling times (0, 60, 120 s) were analyzed. The results show that the simulated thermal cycle curve and residual stress during arc additive manufacturing agreed with the test results, and the relative errors were less than 9% and 3%, respectively, verifying the accuracy of the model. Compared with unidirectional deposition path, the reciprocating deposition path could improve the homogeneity of heat distribution and stress field distribution of the formed parts; the influence area of stress field and heat accumulation was relatively small, the temperature and residual stress were relatively low, and the deformation symmetry was relatively good. With increasing interlayer cooling time, the heat accumulation, residual stress and deformation decreased, but the decrease amplitude was reduced gradually. The forming quality of arc additive manufactured GH4169 nickel-base superalloy was good by applying the reciprocating deposition path and interlayer cooling for 60 s.