A novel on-line vortex cooling powered by low-cost compressed air was proposed to reduce common defects such as low forming precision, coarse grains, and pores caused by heat accumulation in the Wire Arc Additive Manufacturing (WAAM) of aluminum alloy. The impacts of interlayer cooling (IC), substrate cooling (SC), on-line cooling (OL), and natural cooling (NC) processes were compared on the morphology, microstructure, and mechanical properties of as-deposited walls, revealing that the OL process significantly lowers the interlayer temperature and improves forming precision. The high cooling rate produced by the OL process reduced the absorption of hydrogen in the molten pool, lowering porosity. Furthermore, the grains are refined due to the developed undercooling. However, the high cooling rate enhanced the segregation potential of Mg element and raised the content of the β phase. Conclusively, the maximum tensile strength, elongation, and microhardness of the as-deposited wall are achieved via the OL process, and the fine-grain strengthening mechanism plays an important role in improving mechanical properties. The OL process is cheaper and poses a significant effect; it is highly suitable for the additive manufacturing of complex components compared with other forced cooling processes.

Under extreme working conditions such as high-speed driving on roads with a large road surface unevenness coefficient, turning on a road with a low road surface adhesion coefficient, and emergency acceleration and braking, a vehicle’s stability deteriorates sharply and reduces ride comfort. There is extensive existing research on vehicle active suspension control, trajectory tracking, and control methods. However, most of these studies focus on conventional operating conditions, while vehicle stability analysis under extreme operating conditions is much less studied. In order to improve the stability of the whole vehicle under extreme operating conditions, this paper investigates the stability of a vehicle under extreme operating conditions based on linear quadratic regulator (LQR) control. First, a seven degrees of freedom (7-DOF) dynamics model of the whole vehicle is established based on the use of electromagnetic active suspension, and then an LQR controller of the electromagnetic active suspension is designed. A joint simulation platform incorporating MATLAB and CarSim was built, and the CarSim model is verified by real vehicle tests. Finally, the stability of the vehicle under four different ultimate operating conditions was analyzed. The simulation results show that the root mean square (RMS) values of body droop acceleration and pitch angle acceleration are improved by 57.48% and 28.81%, respectively, under high-speed driving conditions on Class C roads. Under the double-shift condition with a low adhesion coefficient, the RMS values of body droop acceleration, pitch acceleration, and roll angle acceleration are improved by 58.25%, 55.41%, and 31.39%, respectively. These results indicate that electromagnetic active suspension can significantly improve vehicle stability and reduce driving risk under extreme working conditions when combined with an LQR controller.