基于图像处理与数值仿真辅助的电弧增材成形研究

为解决Fronius CMT TPS3200焊接电源提供的焊接模式(CMT或CMT+Pulse)与增材策略(单向或往复路径)的选择问题，在相同线能量密度条件下，基于不同模式的单道单层优质焊道成形，探索了单道多层的层宽、层高变化规律，并结合图像处理与数值仿真评价单道10层的增材试验。研究发现，针对焊道成形，CMT+Pulse模式与CMT模式分别从第4层和第3层开始趋于稳定。为优选扫描策略，通过顶层焊道成形和数值仿真结果对比，确定了往复路径优于单向路径。在往复路径下，CMT模式的焊道成形均优于CMT+Pulse模式。研究结果表明，CMT模式率先达到散热稳定条件，结合优选往复路径，在焊道成形方面具有优势，为后续电弧增材奠定了基础。

Study on Wire Arc Additive Manufacturing Forming Based on Image Processing and Numerical Simulation

To solve the selection problem of welding mode (CMT or CMT + Pulse) and additive strategy (unidirectional or reciprocating path) provided by Fronius CMT TPS3200 welding power supply, under the same linear energy density, based on the high-quality forming of single-track single-layer welding bead with different modes, the variation law of layer width and layer height toward single-track multi-layers is studied, and single-track 10-layers bead forming is evaluated by combining image processing and numerical simulation. It is found that the weld bead forming of CMT+Pulse mode and CMT mode tend to reach stability from the fourth and third layer, respectively. In order to select optimal scanning strategy, the reciprocating path for bead forming is better than the unidirectional path based on the aspect of numerical simulation and evaluation of top weld bead forming. Under the reciprocating path, the weld bead forming of CMT mode is better than CMT+Pulse mode. The results show that the CMT mode preferred to achieve the heat dissipation stability condition, and combined with the optimal reciprocating path, it has advantages in welding bead forming, which lays the foundation for subsequent arc additive materials.