激光熔融制造<strong>Ti6Al4V</strong>合金薄壁件变形的数值模拟

doi:10.11901/1005.3093.2025.371

材料研究学报

2026, Vol. 40

Issue (10): 792-800 DOI: 10.11901/1005.3093.2025.371

研究论文

本期目录 | 过刊浏览

激光熔融制造Ti6Al4V合金薄壁件变形的数值模拟

孙文博¹, 李应举², 冯小辉²(

), 邱义², 董志国², 曹大力¹(

)

^1.沈阳化工大学材料科学与工程学院沈阳 110142
^2.中国科学院金属研究所沈阳 110016

Numerical Simulation of Deformation Control for Laser Additive Manufacturing of Ti6Al4V Thin-walled Part

SUN Wenbo¹, LI Yingju², FENG Xiaohui²(

), QIU Yi², DONG Zhiguo², CAO Dali¹(

)

^1.School of Materials Science and Engineering, Shenyang University of Chemical Technology, Shenyang 110142, China
^2.Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

引用本文:

孙文博, 李应举, 冯小辉, 邱义, 董志国, 曹大力. 激光熔融制造Ti6Al4V合金薄壁件变形的数值模拟[J]. 材料研究学报, 2026, 40(10): 792-800.
Wenbo SUN, Yingju LI, Xiaohui FENG, Yi QIU, Zhiguo DONG, Dali CAO. Numerical Simulation of Deformation Control for Laser Additive Manufacturing of Ti6Al4V Thin-walled Part[J]. Chinese Journal of Materials Research, 2026, 40(10): 792-800.

全文: PDF(8464 KB) HTML

摘要:

使用有限元软件模拟一种Ti6Al4V合金弯管薄壁件的激光粉末床熔融 (Laser powder bed fusion, L-PBF)工艺过程，预测其变形和变形量，研究了激光功率和激光扫描速度等主要工艺参数对薄壁件变形量的影响。结果表明，优化的激光功率和扫描速度分别为180 W和1.2 m/s。在L-PBF实验中使用三坐标测量仪测出的薄壁件尺寸偏差证实，这种模拟结果与测量结果的一致性良好。

关键词 ：金属材料, 数值模拟, 激光粉末床熔融技术, 固有应变, 薄壁件

Abstract：

Laser powder bed fusion (L-PBF) technique demonstrates tremendous potential in application, but this process tends to generate significant residual stresses within workpieces, potentially causing deformation. Herein, the L-PBF process for a thin-walled Ti6Al4V alloy elbow component was numerically simulated by means of finite element software in terms of the effect of the variation of laser powers and the speed of laser scanning on the deformation of the prepared workpiece of Ti6Al4V alloy. The simulation accurately predicted the deformation trends and magnitudes, quantitatively revealing the influence of laser power and scanning speed on the workpiece deformation. The optimal parameter combination was determined to be 180 W laser power and 1.2 m/s scanning speed based on the numerical investigation. Through L-PBF, a thin-walled Ti6Al4V alloy elbow component was fabricated, of which the deviations of dimensions were measured using a coordinate measuring machine, revealing good consistency between the measured data and the simulation results.

Key words： metallic materials numerical simulation laser powder bed fusion inherent strain thin-walled part

收稿日期: 2025-12-18

ZTFLH:

TN249

通讯作者: 曹大力，副教授，caodali2008@163.com，研究方向为高强铝合金和铜基功能材料；
冯小辉，高级工程师，xhfeng@imr.ac.cn，研究方向为先进金属材料凝固与成形过程

Corresponding author: CAO Dali, Tel: 18604047649, E-mail: caodali2008@163.com;
FENG Xiaohui, Tel: 13609838580, E-mail: xhfeng@imr.ac.cn

作者简介: 孙文博，男，1997年生，硕士生

	服务

	把本文推荐给朋友
	加入引用管理器
	E-mail Alert
	RSS
	作者相关文章
	孙文博
	李应举
	冯小辉
	邱义
	董志国
	曹大力
44.8K

链接本文:

https://www.cjmr.org/CN/10.11901/1005.3093.2025.371 或 https://www.cjmr.org/CN/Y2026/V40/I10/792

图1 三维模型网格的划分

表1 Ti6Al4V合金的属性

图2 Ti6Al4V合金的特性曲线

图3 不同构建高度L-PBF弯管薄壁件的应力-时间曲线

图4 L-PBF弯管薄壁件的三轴方向位移量

图5 在不同激光功率条件下模拟尺寸偏差统计图与X、Y、Z三向轴向位移云图

图6 在不同扫描速度条件下模拟尺寸偏差统计图和X、Y、Z三向轴向位移云图

图7 尺寸偏差的模拟结果与实验测量结果的对比

表2 工件中不同位置截面的测量数据

图8 模拟结果节点统计

[1]	Gao H J, Li X, Wu Q, et al. Effects of residual stress and equivalent bending stiffness on the dimensional stability of the thin-walled parts [J]. Int. J. Adv. Manuf. Technol., 2022, 119: 4907 doi: 10.1007/s00170-021-08252-3
[2]	Wang N, Li W B, Pang J C, et al. Tensile properties and deformation mechanism of additive manufacturing superalloy at different temperatures [J]. Chin. J. Mater. Res., 2025, 39(1): 1 doi: 10.11901/1005.3093.2024.106
[2]	王娜, 李文彬, 庞建超等. 增材制造高温合金在不同温度下的拉伸性能与变形机制 [J]. 材料研究学报, 2025, 39(1): 1
[3]	Jiang M L, Dai B B, Chen L, et al. Effect of building dimensions by selective laser melting on pitting properties of 304L stainless steel [J]. Chin. J. Mater. Res., 2023, 37(5): 353 doi: 10.11901/1005.3093.2021.625
[3]	蒋梦蕾, 代斌斌, 陈亮等. 选区激光熔化成形尺寸对304L不锈钢点蚀性能的影响 [J]. 材料研究学报, 2023, 37(5): 353 doi: 10.11901/1005.3093.2021.625
[4]	Zhou Z G, Liu Y Z, Liu X H, et al. Microstructure evolution and mechanical properties of in-situ Ti6Al4V–TiB composites manufactured by selective laser melting [J]. Composites, 2021, 207B: 108567
[5]	Zheng Z P, Jin X, Bai Y C, et al. Microstructure and anisotropic mechanical properties of selective laser melted Ti6Al4V alloy under different scanning strategies [J]. Mater. Sci. Eng., 2022, 831A: 142236
[6]	Zang T, Yang P F, Zhao Y, et al. Effect of hot isostatic pressing on notch sensitivity of Ti-6Al-4V Ti-alloy prepared by selective laser melting [J]. Chin. J. Mater. Res., 2025, 39(10): 791 doi: 10.11901/1005.3093.2024.463
[6]	臧涛, 杨朋飞, 赵元等. 热等静压SLM Ti-6Al-4V合金的缺口敏感性 [J]. 材料研究学报, 2025, 39(10): 791
[7]	Nguyen H D, Pramanik A, Basak A K, et al. A critical review on additive manufacturing of Ti-6Al-4V alloy: microstructure and mechanical properties [J]. J. Mater. Res. Technol., 2022, 18: 4641 doi: 10.1016/j.jmrt.2022.04.055
[8]	Kushwaha A, Subramaniyan A K, Kenchappa N B, et al. Microstructure, mechanical, and wear properties of thin-walled Ti6Al4V parts produced using laser powder bed fusion technique [J]. Mater. Lett., 2022, 308: 131138 doi: 10.1016/j.matlet.2021.131138
[9]	Zhang Z Y, Yang X, Song F, et al. Assessment of microstructural evolution and associated tensile behavior in thin-walled Ti6Al4V parts manufactured via selective laser melting [J]. Mater. Charact., 2022, 194: 112481 doi: 10.1016/j.matchar.2022.112481
[10]	Abarca M J, Darabi R, de Sa J C, et al. Multi-scale modeling for prediction of residual stress and distortion in Ti-6Al-4V semi-circular thin-walled parts additively manufactured by laser powder bed fusion (LPBF) [J]. Thin-Walled Struct., 2023, 182: 110151 doi: 10.1016/j.tws.2022.110151
[11]	Liu Z F, Huang Y D, Yang X, et al. Preparation of graphene/Ni-Cu alloy composite on Ni-Cu alloy template made by selective laser melting [J]. Chin. J. Mater. Res., 2021, 35(1): 1 doi: 10.11901/1005.3093.2020.185
[11]	刘主峰, 黄耀东, 杨潇等. 基于激光选区熔化成形Ni-Cu合金模板的Ni-Cu-石墨烯复合材料的制备 [J]. 材料研究学报, 2021, 35(1): 1 doi: 10.11901/1005.3093.2020.185
[12]	Lu S J, Li Y, Zhen S Y, et al. Influence of process parameters on the microstructures, residual stresses and mechanical properties of TA15 titanium alloy fabricated by L-PBF [J]. Mater. Sci. Eng., 2025, 927A: 147990
[13]	Zhang W Y, Tong M M, Harrison N M. Scanning strategies effect on temperature, residual stress and deformation by multi-laser beam powder bed fusion manufacturing [J]. Addit. Manuf., 2020, 36: 101507
[14]	Bang G B, Han S J, Park J H, et al. Effect of heating scan strategy using low energy density on relief of thermal residual stress in L-PBF process for CoCrMo alloy [J]. J. Mater. Res. Technol., 2024, 29: 2720 doi: 10.1016/j.jmrt.2024.01.244
[15]	Ramani K S, He C, Tsai Y L, et al. SmartScan: an intelligent scanning approach for uniform thermal distribution, reduced residual stresses and deformations in PBF additive manufacturing [J]. Addit. Manuf., 2022, 52: 102643
[16]	Dong W, Liang X, Chen Q, et al. A new procedure for implementing the modified inherent strain method with improved accuracy in predicting both residual stress and deformation for laser powder bed fusion [J]. Addit. Manuf., 2021, 47: 102345
[17]	Li K, Zhang M, Hou Y Q, et al. Multi-scale simulation of residual stress and deformation of large-size hollow parts fabricated by laser-based powder bed fusion [J]. Thin-Walled Struct., 2024, 198: 111743 doi: 10.1016/j.tws.2024.111743
[18]	Mohanraj J, Sahu J. Numerical prediction of residual stress and distortion for laser powder bed fusion (LPBF) AM process of Ti-6Al-4V [J]. Simul. Modell. Pract. Theory, 2025, 140: 103094 doi: 10.1016/j.simpat.2025.103094
[19]	Liu Z Z, Ding M L, Xie J X. Advancements in digital manufacturing for metal 3D printing [J]. Acta Metall. Sin., 2024, 60(5): 569 doi: 10.11900/0412.1961.2023.00416
[19]	刘壮壮, 丁明路, 谢建新. 金属3D打印数字化制造研究进展 [J]. 金属学报, 2024, 60(5): 569 doi: 10.11900/0412.1961.2023.00416
[20]	Alikarami S, Nakhodchi S. Stress relaxation of inconel 718 superalloy manufactured by selective laser melting (SLM) [J]. Int. J. Press. Vessels Pip., 2025, 214: 105442 doi: 10.1016/j.ijpvp.2025.105442
[21]	Ahmed N, Barsoum I, Al-Rub R K A. Numerical investigation of residual stresses in thin-walled additively manufactured structures from selective laser melting [J]. Heliyon, 2023, 9(9): e19385 doi: 10.1016/j.heliyon.2023.e19385
[22]	Zhang Z D, Ibhadode O, Shahabad S I, et al. High-resolution inherent strain method using actual layer thickness in laser powder bed fusion additive manufacturing with experimental validations [J]. J. Mater. Res. Technol., 2024, 30: 6576 doi: 10.1016/j.jmrt.2024.05.047
[23]	Mukalay T A, Trimble J A, Mpofu K, et al. Selective laser melting: evaluation of the effectiveness and reliability of multi-scale multiphysics simulation environments [J]. Heliyon, 2024, 10(4): e25706 doi: 10.1016/j.heliyon.2024.e25706
[24]	Kwabena Adomako N, Kim S H, Yoon J H, et al. Finite element modeling of residual stress at joint interface of titanium alloy and 17-4PH stainless steel [J]. Metals, 2021, 11(4): 629 doi: 10.3390/met11040629
[25]	Ma Q P, Mesicek J, Fojtik F, et al. Residual stress build-up in aluminum parts fabricated with SLM technology using the bridge curvature method [J]. Materials, 2022, 15(17): 6057 doi: 10.3390/ma15176057
[26]	Dogea R, Yan X T, Millar R. Additive manufacturing process design for complex aircraft components [J]. Int. J. Adv. Manuf. Technol., 2022, 123(11): 4195 doi: 10.1007/s00170-022-10413-x
[27]	Sun X F, Song W, Liang J J, et al. Research and development in materials and processes of superalloy fabricated by laser additive manufacturing [J]. Acta Metall. Sin., 2021, 57(11): 1471 doi: 10.11900/0412.1961.2021.00371
[27]	孙晓峰, 宋巍, 梁静静等. 激光增材制造高温合金材料与工艺研究进展 [J]. 金属学报, 2021, 57(11): 1471 doi: 10.11900/0412.1961.2021.00371
[28]	Lu X F, Chen C, Zhang G H, et al. Thermo-mechanical simulation of annealing heat treatment of Ni-based GH4099 superalloy made by laser powder bed fusion [J]. Addit. Manuf., 2023, 73: 103703
[29]	Song B, Zhang J L, Zhang Y J, et al. Research progress of materials design for metal laser additive manufacturing [J]. Acta Metall. Sin., 2023, 59(1): 1 doi: 10.11900/0412.1961.2022.00026
[29]	宋波, 张金良, 章媛洁等. 金属激光增材制造材料设计研究进展 [J]. 金属学报, 2023, 59(1): 1
[30]	Wang D, Huang J H, Tan C L, et al. Review on effects of cyclic thermal input on microstructure and property of materials in laser additive manufacturing [J]. Acta Metall. Sin., 2022, 58(10): 1221 doi: 10.11900/0412.1961.2021.00310
[30]	王迪, 黄锦辉, 谭超林等. 激光增材制造过程中循环热输入对组织和性能的影响 [J]. 金属学报, 2022, 58(10): 1221
[31]	Singh U P, Swaminathan S, Phanikumar G. Thermo-mechanical approach to study the residual stress evolution in part-scale component during laser additive manufacturing of alloy 718 [J]. Mater. Des., 2022, 222: 111048 doi: 10.1016/j.matdes.2022.111048
[32]	Ke L D, Yin J, Zhu H H, et al. Numerical simulation of stress evolution of thin-wall titanium parts fabricated by selective laser melting [J]. Acta Metall. Sin., 2020, 56(3): 374 doi: 10.11900/0412.1961.2019.00198
[32]	柯林达, 殷杰, 朱海红等. 钛合金薄壁件选区激光熔化应力演变的数值模拟 [J]. 金属学报, 2020, 56(3): 374 doi: 10.11900/0412.1961.2019.00198
[33]	Wang M Y, Li S J, He Z H, et al. Effect of process parameters on density and compressive properties of Ti5553 alloy block prepared by SLM [J]. Chin. J. Mater. Res., 2025, 39(8): 583 doi: 10.11901/1005.3093.2024.398
[33]	王铭宇, 李述军, 和正华等. 激光功率和扫描速度对SLM制备Ti5553合金性能的影响 [J]. 材料研究学报, 2025, 39(8): 583 doi: 10.11901/1005.3093.2024.398

[1]	何一梅, 付志豪, 杨超云, 刘航, 刘朋, 李星, 石帅, 赵燕青, 栾义坤, 李殿中. 稀土Ce对渗碳齿轮钢摩擦磨损性能的影响[J]. 材料研究学报, 2026, 40(9): 641-652.
[2]	李冰冰, 徐磊, 尹一峰, 田晓生, 卢正冠, 吴杰. 热等静压参数对Ti₂AlNb粉末合金力学性能的影响[J]. 材料研究学报, 2026, 40(9): 653-664.
[3]	张丰之, 吴云胜, 管现军, 侯介山, 周兰章. Al+Ti对一种Ni-Cr合金组织及力学性能的影响[J]. 材料研究学报, 2026, 40(9): 665-676.
[4]	郭非凡, 马继刚, 陈丽娟, 谢伟智, 魏博, 马瑞, 安田田, 李奕华, 李新月. 高氯煤烟中的氯腐蚀锅炉换热器的机理[J]. 材料研究学报, 2026, 40(9): 697-709.
[5]	刘志辉, 张世一, 邹爱华, 张凱尧, 曾卓, 张世翼, 涂嘉剑, 严旭. 激光冲击强化对 Al_xCoCrFeNi高熵合金激光熔覆层组织及耐磨性能的影响[J]. 材料研究学报, 2026, 40(9): 710-720.
[6]	胡明, 王啟睿, 邱建科, 雷晓飞, 张金虎, 董利民, 杨锐. 拉拔变形量对超高强钛合金棒材强塑性的影响[J]. 材料研究学报, 2026, 40(8): 561-571.
[7]	杨垒, 尚学文, 田晓生, 高慧颖, 徐磊. 粉末冶金热等静压工艺成形TC11合金长时间热暴露后的力学性能[J]. 材料研究学报, 2026, 40(8): 572-582.
[8]	陈尧, 陈志勇, 柏春光. Ti₂AlNb合金薄板的微观组织、织构和力学性能[J]. 材料研究学报, 2026, 40(8): 583-594.
[9]	宋肖桐, 陈思旭, 邱建科, 胡明, 张明杰, 昝晓东, 雷家峰. 热加工对紧固件用Ti55531棒材断裂韧性的影响[J]. 材料研究学报, 2026, 40(8): 595-604.
[10]	张铭原, 闻明, 李思勰, 张滨, 张广平. 制备工艺参数对磁控溅射Ni5Pt薄膜的影响[J]. 材料研究学报, 2026, 40(8): 613-623.
[11]	包方玄, 宫明龙, 刘恩瑞, 刘凤芳, 白静, 高秋志. FeCoNiCuSi _x B_{1 -}_x 高熵合金力学性能的优化和高压强化机制[J]. 材料研究学报, 2026, 40(7): 481-496.
[12]	谢贞俊, 朱艳坤, 赵振凯, 陆彦地, 周相海, 曹明, 张鹏, 张哲峰. 一种含复合夹杂物的贝马复相钢疲劳开裂机制[J]. 材料研究学报, 2026, 40(7): 519-527.
[13]	王娜, 兰中华, 屈金萌, 刘艳云, 李万喜, 刘慧超, 冯丽萍. 纤维素衍生多孔碳的制备及其电化学储能性能[J]. 材料研究学报, 2026, 40(7): 535-542.
[14]	周明晗, 陈双龙, 王秋实, 王雪娇, 刘才龙. Si₃N₄(Si₃N₄:Ho³⁺/Yb³⁺)分支纳米线的制备及其温度传感性能[J]. 材料研究学报, 2026, 40(7): 543-552.
[15]	郑沁园, 郑成武, 路轶, 朱海龙, 刘朋, 栾义坤, 李殿中. 软化退火对冷轧中锰钢再结晶和相变的影响[J]. 材料研究学报, 2026, 40(6): 401-413.

Viewed

Full text

Abstract

Cited

Shared

Discussed