| 摘要: |
| 针对航天器在轨修复中金属电阻熔丝成形质量差、工艺稳定性不足的难题，本研究系统揭示了低压环境下关键工艺参数的协同调控机制。通过构建电阻熔丝沉积实验平台，结合高速摄像与多目标优化方法，量化分析了电流幅值、送丝速度、移动速度、预热温度及位置对成形形貌与界面结合的耦合作用规律。实验表明，低压环境通过增强辐射散热和抑制氧化，显著改变熔滴过渡及熔池凝固；电流幅值100 A电磁力与表面张力达到动态平衡，熔滴过渡频率稳定，飞溅率降低至5%；送丝速度0.8 m/min实现能量-质量传递匹配，形貌系数优化；移动速度为1.6 mm/s时熔池驻留时间为1.54 s，定向凝固抑制微裂纹；预热位置x1使界面剪切强度提升。基于NSGA-Ⅱ算法构建的多参数协同优化模型，确定最佳工艺窗口。建立了低压环境工艺参数-熔滴/熔池行为-成形的定量映射关系，为航天器在轨高精度修复提供了理论依据与工程化解决方案。 |
| 关键词: 在轨修复 电阻熔丝 工艺参数 多目标优化 |
| 基金项目:国家自然科学基金青年项目（52305387）。 |
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| Research on Synergistic Regulation Mechanism of Metal Resistance Wire for On-orbit Repair |
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Yuan Chengwei1, Liang Xinxing1, Zhang Guokai2, Li Debao2, Chen Shujun2
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1. College of Mechanical Engineering, Shandong University of Technology, Zibo 255000;2. College of Mechanical and Energy Engineering, Beijing University of Technology, Beijing 100124
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| Abstract: |
| Addressing the challenges of poor forming quality and insufficient process stability of metal resistance wire in spacecraft on-orbit repair, this study systematically reveals the synergistic regulation mechanism of key process parameters in a low-pressure environment. By establishing a resistance wire deposition experimental platform combined with high-speed imaging and multi-objective optimization methods, the coupling effects of current amplitude, wire feed speed, travel speed, preheating temperature, and position on forming morphology and interfacial bonding were quantitatively analyzed. Experimental results demonstrate that the low-pressure environment significantly alters molten pool dynamics by enhancing radiative heat dissipation and suppressing oxidation. At a current amplitude of 100 A, electromagnetic forces and surface tension reach dynamic equilibrium, stabilizing droplet transition frequency and reducing the spatter rate to 5%. A wire feed speed of 0.8 m/min achieves energy-mass transfer matching, optimizing morphology. A travel speed of 1.6 mm/s ensures a molten pool dwell time of 1.54 s, suppressing microcracks through directional solidification. Preheating at position x1 enhances interfacial shear strength. A multi-parameter collaborative optimization model based on the NSGA-Ⅱ algorithm identifies the optimal process window. Quantitative mapping relationships between low-pressure process parameters, droplet/pool behavior, and forming quality are established, providing theoretical foundations and engineering solutions for high-precision on-orbit spacecraft repair. |
| Key words: on-orbit repair resistance wire process parameters multi-objective optimization |
