Optimization of shape-forming accuracy in arc-striking and arc-extinguishing areas of weld bead by torch hovering for directed energy deposition-arc manufactured nickel aluminum bronze alloy component

In the process of directed energy deposition-arc (DED-arc), the geometrical shape of weld bead in arc-striking (AS) and arc-extinguishing (AE) areas are usually inconsistent with that in the middle section, which directly affects the forming accuracy of component thus needs to be optimized. In this paper, high-speed photography is used to observe the molten pool behavior of nickel aluminum bronze (NAB) bead deposition, and the causes of abnormal bead shape in the AS and AE areas are analyzed. On that basis, an optimization method for AS and AE is put forward. In the AS area, the welding current and travel speed are increased. And after the arc strikes, a hovering time is used during which the torch hovers at the AS point. In the AE area, the welding current is gradually reduced while the torch keeps hovering at the AE point. Then, the optimization effect of AS parameters on the bead shape are explained through factorial experiments, and the optimization effects of AE parameters are explained through orthogonal experiments. At the same time, the optimal parameter combination of AS and AE is obtained. With the proposed method and the optimal parameters, the height and width deviation of the deposited single bead are controlled within 5%. After adopting the optimization method, the effective height ratio of the DED-arc–manufactured NAB thin wall is increased from 67.5% to 91.5% under the unidirectional deposition path, which is also increased from 88.9% to 98.3% under the bidirectional deposition path.