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<p>Wire arc additive manufacturing is an important new way to achieve high-efficiency and high-quality formation and manufacturing of large complex metal components. To address the issues of poor process stability and low forming accuracy of the thin-walled sidewall in the CMT-PADV process mode, this study optimized the mutual coordination of current and voltage by adjusting the arc correction coefficient, thereby indirectly modifying the arc shape. The effects of different arc correction coefficients on droplet transfer behavior, electrical signal characteristics, and the forming accuracy of thin-walled sidewalls were systematically investigated. The results indicated that as the arc correction coefficient shifted from negative to positive, the occurrence of sub-jet transfer was effectively suppressed due to an increased arc length, which minimized contact between the droplet, wire tip, and molten pool. This adjustment reduced the high concentration of aluminum vapor caused by “necking” fractures of the wire and subsequently decreased spatter. As a result, the formation of a secondary peak arc was inhibited due to the lack of a conductive medium, leading to enhanced stability in droplet transfer and electrical signal characteristics. Furthermore, when the arc correction coefficient exceeded 0% (up to 10%), the arc pressure gradually reached equilibrium with the arc shear force and the Marangoni force in the molten pool, causing the defect at the top of the thin-walled wall to disappear progressively and significantly improving the forming accuracy of the sidewall.</p>

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Droplet Transfer and Formation in Aluminum Alloy CMT-PADV Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年9月2日

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  • Hang Yin,
  • Yongquan Han,
  • Zhenbang Sun,
  • Maohua Du,
  • Liguo Zhang,
  • Linghong Meng

摘要

Wire arc additive manufacturing is an important new way to achieve high-efficiency and high-quality formation and manufacturing of large complex metal components. To address the issues of poor process stability and low forming accuracy of the thin-walled sidewall in the CMT-PADV process mode, this study optimized the mutual coordination of current and voltage by adjusting the arc correction coefficient, thereby indirectly modifying the arc shape. The effects of different arc correction coefficients on droplet transfer behavior, electrical signal characteristics, and the forming accuracy of thin-walled sidewalls were systematically investigated. The results indicated that as the arc correction coefficient shifted from negative to positive, the occurrence of sub-jet transfer was effectively suppressed due to an increased arc length, which minimized contact between the droplet, wire tip, and molten pool. This adjustment reduced the high concentration of aluminum vapor caused by “necking” fractures of the wire and subsequently decreased spatter. As a result, the formation of a secondary peak arc was inhibited due to the lack of a conductive medium, leading to enhanced stability in droplet transfer and electrical signal characteristics. Furthermore, when the arc correction coefficient exceeded 0% (up to 10%), the arc pressure gradually reached equilibrium with the arc shear force and the Marangoni force in the molten pool, causing the defect at the top of the thin-walled wall to disappear progressively and significantly improving the forming accuracy of the sidewall.