Abstract:

Lightweight and high-performance aluminum alloys are crucial for the weight reduction design of aerospace equipment. Consequently, spray forming with rapid solidification technology has garnered increasing attention for the fabrication of high-strength aluminum alloys. To meet the demands of large-scale aerospace components, a multi-nozzle collaborative system is required to achieve larger billet diameters. During the scanning deposition process, where atomization cones from multiple nozzles intersect the deposition interface at specific inclination angles, it is essential to ensure uniform distribution of the molten material and maintain a flat, stable growth of the billet’s top surface. These factors are key to producing high-quality billets with dense and uniform microstructures. The process parameters associated with multi-nozzle configurations directly influence the scanning trajectories of atomized droplets and the material deposition state at the interface, playing a decisive role in billet growth. Aiming to produce large-scale billets with consistent morphology and uniform deposition quality, a multi-nozzle Deposition Surface Behavior Model (DSBM) is established based on microscale scanning deposition heights. Additionally, the GA-DSBM intelligent optimization method is employed to simulate, analyze, and optimize key process parameters during deposition. BY the optimized parameters, spray forming experiments were conducted, which shows that the surface unevenness was lower than 7.52 mm when spray forming a billet with a diameter of 600 mm. It meets the design requirements and confirming the feasibility of the intelligent optimization method.

Key words:

spray forming；multi-nozzle；deposition surface；uniform deposition ,