In the additive manufacturing (AM) process, metal powder can be directly used to produce metal components. Unfortunately, a large thermal gradient is developed during the AM process, which leads to the generation of residual stress and complex shape-distortions. In this study, the influence of the geometrical size and structural features of a hollow Ti-alloy blade prepared by the AM process on the shape-distortion behavior was systematically investigated using the three-dimensional (3D) blue-light scanning technology. The results indicated that the concentrated residual stress was developed on the surface of the blade. The compressive residual stress induced a bulging distortion, while the tensile residual stress resulted in denting distortion on the blade surfaces. When the blade height and torsion angle increased, the shape-distortion was aggravated owing to the accumulation of microscopic strain and the elevated temperature gradient. However, the shape-distortion mitigated when the wall thickness significantly increased or the stiffened plates were set within the blade cavities, owing to a strengthening structural constraint which inhibited the distortion behavior. In addition, a control method for the shape-distortion during AM process was able to implement based on the proper optimization of the geometrical sizes and structural features of complex 3D-printed components.

中文翻译：

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几何尺寸和结构特征对增材制造空心钛合金叶片形变行为的影响

在增材制造 (AM) 工艺中，金属粉末可直接用于生产金属部件。不幸的是，在增材制造过程中会产生很大的热梯度，这会导致产生残余应力和复杂的形状变形。在这项研究中，使用三维（3D）蓝光扫描技术系统地研究了通过增材制造工艺制备的空心钛合金叶片的几何尺寸和结构特征对形状畸变行为的影响。结果表明，叶片表面产生了集中的残余应力。残余压应力引起叶片鼓胀变形，残余拉伸应力导致叶片表面凹陷变形。当叶片高度和扭转角增加时，由于微观应变的积累和升高的温度梯度，形状扭曲加剧。然而，当壁厚显着增加或加强板设置在叶片腔内时，由于加强结构约束抑制了变形行为，形状变形得到缓解。此外，基于对复杂 3D 打印部件的几何尺寸和结构特征的适当优化，能够实现增材制造过程中形状变形的控制方法。由于加强结构约束抑制了扭曲行为。此外，基于对复杂 3D 打印部件的几何尺寸和结构特征的适当优化，能够实现增材制造过程中形状变形的控制方法。由于加强结构约束抑制了扭曲行为。此外，基于对复杂 3D 打印部件的几何尺寸和结构特征的适当优化，能够实现增材制造过程中形状变形的控制方法。