金属增材制造技术是以数字模型为基础，采用激光、电弧和电子束等方式将金属粉末或丝材逐层堆积黏结，从而实现复杂零部件快速成形的数字化智能制造技术，已广泛应用于航空航天、生物医疗、液压及模具制造等领域关键复杂和高性能金属零部件的制造。然而，成形零件因制造过程中的台阶效应、球化效应和粉末粘附等因素导致表面质量差，亟需后续的光整加工才能满足使役要求。

        本文聚焦工具可达性差和操作可视性弱的复杂内通道零件光整加工技术难题，开展电化学光整加工技术基础研究，主要研究内容如下：

        (1) 揭示了激光选区熔化成形316L不锈钢沿不同平面取向的微观形貌和组织特征，以及在水基和醇基溶液中的电化学溶解机理和光整形貌演变规律。增材制造成形零件上表面分布着紧密搭接的平行熔道和大量金属粉末颗粒，而侧表面上有更多的黏附金属颗粒和鱼鳞状层带凸起；横截面晶粒是沿不同方向生长的近等轴柱状和枝状晶，而纵截面晶粒是沿成形方向生长的细条状晶；成形试件在水基溶液中形成了稳定的钝化膜，使其在较小电流密度( i < 10A·cm^-2)时电流效率较低，且表面呈现出不利于光整加工的中空网状形貌。而在NaCl乙二醇溶液中基本没有钝化现象，小电流密度( i < 4A·cm^-2)加工时副反应少而电流效率高，且能获得较高表面质量。

        (2) 提出了工具组件在NaNO₃水溶液中往复运动的电解磨削组合高效光整加工技术。将电化学加工高效与磨削加工高质量的优势相结合，设计出包含粗精磨轮和阴极的工具组件。通过分析不同工具及其加工表面的微观相貌和粗糙度，并结合EDX和XPS检测技术，揭示了磨轮刮除氧化层、金属颗粒及产物，阴极电化学溶解带状凸起的材料去除机理；优化设计出带有导向结构的工具组件，改善了电解液流动速度和均匀性；通过开展三组不同进给速度的光整加工试验，验证了组合光整加工技术的可行性，并优选出0.1mm/min为合理的工具组件进给速度。在保证加工时间一致前提下，对比了单次慢速和多次快速两种工具运动方式的光整效果，后者磨削刮除作用更强，大量的黑色电解产物和钝化膜被去除，表面更加光亮，粗糙度值较前者也有少许降低。

        (3) 提出了NaCl乙二醇溶液中柔性阴极电化学光整加工方法。基于电化学光整加工涉及的多个物理场，对醇基溶液阳极表面离子过饱和层动态形成过程进行了仿真分析和试验验证，揭示了过饱和层对电化学光整加工表面整平过程的影响规律；通过观察试验现象和测试产物成分，明晰了激光选区熔化成形316L不锈钢在NaCl乙二醇溶液中电化学光整加工时的化学反应机理。在较小电参数条件下，阴极表面不仅有大量的H₂析出，还生成了有利于离子过饱和层形成的金属醇盐。当电参数较大时，乙二醇除了被氧化生成各种C2组分物质，还会生成金属氧化物和CO₂气体等副反应；开展了NaCl乙二醇溶液中柔性螺旋阴极电化学光整加工10mm直径的内通道试验，根据流场仿真结果在工件入口和出口处设置了导流段，加工后工件表面呈光亮色泽，没有任何流痕缺陷，入口、中间和出口处的粗糙度值Sa为分别为0.73μm、0.79μm和0.83μm，较初始表面约降低95%，光整加工效果显著。

        (4) 针对复杂内通道大长径比的结构特点，研制出包括电化学光整加工机床、电解液循环装置、运动控制系统、电源和数据采集设备的内通道电化学光整加工系统。根据内通道电化学光整加工的工艺特点和加工方式，提出了系统的总体结构、设计要求和关键设计指标；对机床的床身、运动部件和引电装置等关键部件进行设计；基于监视与控制通用系统(Monitor and Control Generated System, MCGS)软件平台，开发出以可编程控制器为核心的运动控制系统和上位机监控操作系统，实现了Z轴直线运动的闭环控制和Z轴旋转运动的定位调速控制；设计并搭建了包括柱塞计量泵、加热器、冷水机和粗精两级过滤器的电解液循环系统，实现工作介质流量和压力的大范围输出、温度精准控制和高效过滤。

        (5) 基于水基溶液电解磨削组合光整加工和醇基溶液柔性阴极加工的工艺规律，开展了L形、S形和渐变式等典型复杂内通道的电化学光整加工试验。采用电解磨削组合加工方法，在NaNO₃水溶液中完成了L形内通道的光整加工。在直径增加约2%的情况下，粗糙度值Sa较初始表面降低70%以上，光整加工效果显著；针对直径为3mm的S形复杂模具随形内通道，使用柔性阴极在NaCl乙二醇溶液中实现其光整加工，三个典型位置的粗糙度值Sa较初始表面降低了约80%，孔径增加了约0.2mm，满足粗糙度和孔径尺寸精度要求；聚焦某型号航空发动机用渐变式内通道的光整加工需求，基于主通道离散化电场仿真，拟合出电压沿渐变式内通道轴向的变化规律。通过渐变域流场仿真优选出合理的出口形式、供液方式和背压值，以获得均匀稳定的流场分布。在NaCl乙二醇溶液中使用变电压参数完成了渐变式内通道的电化学光整加工，主通道粗糙度值Sa降低约90%以上，且壁厚和倒圆角处半径也都满足加工要求。

        Metal additive manufacturing (MAM) technology is a digital intelligent manufacturing technology based on digital model, which uses laser and electron beam to stack and bond metal powder layer by layer to realize rapid prototyping of complex parts. It has been widely used in the production of key complex and high-performance metal parts in aerospace, biomedical, hydraulic and mold manufacturing and other fields. However, the surface quality of formed parts is poor due to the step effect, spheroidization effect and powder adhesion in the manufacturing process. Therefore, subsequent finishing processes are necessary to meet the service requirements.

        Focusing on the technical challenges of finishing complex internal channel parts with poor tool accessibility and operational visibility, the basic research on electrochemical finishing technology is carried out, and the main research work is summarized as follows:

        (1) The micromorphology and microstructure characteristics of laser selective melting 316L stainless steel (316LSS) along different plane orientations and the electrochemical dissolution mechanism in aqueous-based and alcohol-based solutions are revealed. There are a large number of closely bonded parallel fused channels and metal particles on the upper surface of the parts formed by MAM, while there are more adhesive metal particles and fish-like layer bulges on the side surface; The transverse section grains are near equiaxed columnar and dendritic grains growing along different directions, while the longitudinal section grains are thin strip grains growing along the building direction; The specimen forms a stable passivation film in the aqueous-based solution, which makes its current efficiency low at a low current density (i<10A·cm^-2), and the surface presents a hollowed-out retiform structure which is not conducive to finishing. However, in NaCl glycol solution, there is basically no passivation phenomenon. When processing with low current density (i<4A·cm^-2), there are few side reactions and high current efficiency, and high surface quality can be obtained.

        (2) The high-efficiency polishing technology combined with electrochemical and mechanical (EMCP) in NaNO₃ aqueous solution is proposed. The advantages of high efficiency of electrochemical machining and high quality of grinding are combined, and tool components including rough and fine grinding wheel and cathode are designed; By analyzing the microscopic appearance and roughness of different tools and their machined surfaces, and combining with EDX and XPS detection technology, the material removal mechanism of grinding wheel scraping off oxide layer, metal particles and products, and cathode dissolving strip bulge is revealed; The tool assembly with guide structure is optimized and designed to improve the flow speed and uniformity of electrolyte; Three sets of finishing experiments with different feed rates are carried out to verify the feasibility of combined finishing technology, and the reasonable feed rate of tool components is found to be 0.1mm/min. On the premise of ensuring the same processing time, the polishing effects of single slow and multiple fast tool movements are compared. The latter has a stronger mechanical grinding effect. A large number of black electrolytic products and passivation films are scraped by abrasive particles. The surface is brighter and the roughness value is slightly lower than the former.

        (3) The electrochemical finishing (ECF) with flexible cathode in the NaCl glycol solution is proposed. Based on multiple physical fields involved in the ECF, the dynamic formation process of ionic supersaturated layer on the anode surface of alcohol-based solution is simulated and verified by experiments, and the influence of supersaturated layer on the surface leveling process of electrochemical finishing is revealed; The reaction mechanism of ECF of 316LSS formed by SLM in the NaCl glycol solution is clarified by observing the experimental phenomena and testing the composition of the product. Under the condition of small electrical parameters, a large amount of H₂ is generated on the cathode surface, and metal alkoxide is formed on the anode surface which is conducive to the formation of the supersaturated layer of ions. When the electrical parameter is large, ethylene glycol will not only be oxidized to produce various C2 components, but also produce metal oxides and CO₂ gas and other side reactions; An internal channel (10mm diameter) ECF test with flexible spiral cathode in NaCl glycol solution is carried out. According to the flow field simulation results, a diversion section was set at the inlet and outlet of the workpiece. After processing, the surface of the workpiece is bright, without any flow mark defects. The roughness values Sa at the inlet, middle and outlet are 0.73 μm, 0.79 μm and 0.83 μm, respectively. it is about 95% lower than the initial surface, and the finishing effect is remarkable.

        (4) Aiming at the structural characteristics of complex internal channel with large aspect ratio, the ECF system including machine tool, electrolyte circulation device, motion control system, power supply and data acquisition equipment has been developed. According to the process characteristics and processing methods of the ECF, the overall structure, design requirements and key design indicators of the system are proposed; Design the key parts of the machine tool, such as the bed, moving parts and electric device; The key parts of the machine tool, such as the bed, moving parts and electric device, are designed. Based on the general monitoring and control system platform, the motion control system and the upper computer monitoring operation system with programmable controller are developed, and the closed-loop control of Z-axis linear motion and the positioning and speed control of Z-axis rotation motion are realized; The electrolyte circulation system including plunger metering pump, heater, water chiller and coarse and fine two-stage filter has been designed and built to achieve a wide range of flow and pressure output of working medium, accurate temperature control and efficient filtration.

        (5) Based on the process rules of EMCP with aqueous-based solution and flexible cathode finishing with alcohol-based solution, finishing experiments of typical complex inner channels such as L-shaped, S-shaped and gradient-shaped are carried out. The finishing of L-shaped inner channel is completed in NaNO₃ aqueous solution by EMCP method. In the case of an increase in diameter of about 2%, the roughness value Sa decreases by 70% compared with the initial surface, and the finishing effect is remarkable. The S-shaped complex mold channel with a diameter of 3mm is polished by a flexible cathode in NaCl glycol solution. The roughness value Sa of three typical positions is reduced by about 70% compared with the initial surface, and the aperture is increased by about 0.2mm, which meets the requirements of roughness and aperture size accuracy. Focusing on the gradient internal channel of aeroengine, based on the discrete electric field simulation of the main channel, the change law of voltage along the axial direction of the gradient internal channel is fitted. The reasonable outlet form, liquid supply mode and back pressure value are optimized through the simulation of the flow field in the gradient region to obtain a uniform and stable flow field distribution. In NaCl glycol solution, the gradient inner channel is processed by ECF with variable voltage parameters. The roughness value Sa of the main channel was reduced by more than 90%, and the wall thickness and the radius of the fillet also met the processing requirements.

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