scholarly journals Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)

2021 ◽  
pp. 9-14
Author(s):  
Supasit Manokruang ◽  
Frederic Vignat ◽  
Matthieu Museau ◽  
Maxime Limousin
Keyword(s):  
Additive Manufacturing ◽  
Substrate Temperature ◽  
Process Parameters ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
Cold Metal Transfer ◽  
Wire Feed Speed ◽  
Manufacturing Technologies ◽  
Cold Metal

AbstractAmong Additive Manufacturing technologies, Wire and Arc Additive Manufacturing process is strongly dependent of deposition conditions such as welding parameters, substrate temperature, trajectory. In this research, geometry and temperature evolutions of single beads have been investigated according to process parameters modifications. For our experiment, a heating device have been used in order to control the substrate temperature from room temperature up to 400 °C. Considering the Cold Metal Transfer technology, welding parameters, Wire Feed Speed (WFS) and Travel Speed (TS), have been modified while keeping a constant ratio λ (WFS/TS). Results indicate that weld bead geometry, height (h) and width (w), is influenced by substrate temperature and welding parameters. It has been shown that substrate temperature, itself influenced by process parameters, tends to produce thicker and lower weld beads while it increases.

scholarly journals A model for Manufacturing Large Parts with WAAM Technology

2021 ◽  
Author(s):  
Hoang Thanh Vo ◽  
Christelle Grandvallet ◽  
Frédéric Vignat
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Bead Geometry ◽  
Manufacturing Strategy ◽  
Heat Management ◽  
Cold Metal Transfer ◽  
Manufacturing Method ◽  
Wire Feed Speed ◽  
Component Shape ◽  
Cold Metal

Wire Arc Additive Manufacturing (WAAM) is a metallic additive manufacturing process based on the fusion of metallic wire using an electric arc as a heat source. The challenge associated with WAAM is heat management and understanding bead geometry. The printing process involves high temperatures, which results in the build-up of residual stresses can often cause deformations in a component. All of the process variables, such as torch speed (TS), wire feed speed (WFS), idle time, combine to produce the geometry of the deposit bead that results in the desired component shape. So, determining a method for choosing a good combined parameter process is very important to obtain a high-quality part. This article presents a study on how to use the WAAM process to produce a complexity part of aluminium alloys. The step of the determination process parameter is concentrated to develop in this study. An experimental design is determined to study the influence between the process parameters, for example, WFS, TS, high layer, length of bead. Different samples are made using the Yaskawa robot, using the classic CMT (Cold Metal Transfer) as a manufacturing method, using zigzag filling as a manufacturing strategy with the same WFS and same idle times and different TS, different bead lengths. A new manufacturing method using the zigzag filling strategy is proposed by adding an important step in determining the process parameters. The results indicate that the length of the bead has a significant impact on another parameter of the process.

scholarly journals Wire arc additive manufacturing of mild steel

2018 ◽  
Vol 65 (4) ◽  
pp. 179-186 ◽  
Author(s):  
Damjan Klobčar ◽  
Maja Lindič ◽  
Matija Bušić
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Accuracy ◽  
Welding Parameters ◽  
Welding Robot ◽  
Plasma Welding ◽  
Cold Metal Transfer ◽  
Thin Walls ◽  
Manufacturing Technologies ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

AbstractThis paper presents an overview of additive manufacturing technologies for production of metal parts. A special attention is set to wire arc additive manufacturing (WAAM) technologies, which include MIG/MAG welding, TIG welding and plasma welding. Their advantages compared to laser or electron beam technologies are lower investment and operational costs. However, these processes have lower dimensional accuracy of produced structures. Owing to special features and higher productivity, the WAAM technologies are more suitable for production of bigger parts. WAAM technology has been used together with welding robot and a cold metal transfer (CMT) power source. Thin walls have been produced using G3Si1 welding wire. The microstructure and hardness of produced structures were analysed and measured. A research was done to determine the optimal welding parameters for production of thin walls with smooth surface. A SprutCAM software was used to make a code for 3D printing of sample part.

Cold Metal Transfer Welding of Aluminum 5456 Thin Sheets

2014 ◽  
Vol 1029 ◽  
pp. 140-145 ◽  
Author(s):  
Ionuţ Claudiu Roată ◽  
Alexandru Pascu ◽  
Elena Manuela Stanciu ◽  
Mihai Alin Pop
Keyword(s):  
Mechanical Tests ◽  
Metal Transfer ◽  
Major Influence ◽  
Tensile Behaviour ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Thin Sheets ◽  
Weld Bead Geometry ◽  
Cold Metal Transfer ◽  
Cold Metal

This study aims to determine the optimal parameters for cold metal transfer MIG welding of aluminum thin sheets. Starting from this perspective, the filler material of Al5Mg full wire type and a synergic regime of welding with a low linear energy were used. The characterization of welded joints was achieved by macro – microscopic analyses, mechanical tests (microhardness and tensile) aiming to lower the thermo - mechanically affected zone. The results highlight the major influence of the welding parameters over the weld bead geometry and tensile behaviour of the joint.

Prediction of Weld Bead Geometry in Chromium-Manganese Stainless Steel Gas Tungsten Arc Welded Plates Using Artificial Neural Networks

2013 ◽  
Vol 3 (3) ◽  
pp. 13-41 ◽  
Author(s):  
R. Sudhakaran ◽  
P. S. Siva Sakthivel
Keyword(s):  
Stainless Steel ◽  
Process Parameters ◽  
Weld Bead ◽  
Fractional Factorial ◽  
Welding Parameters ◽  
Width Ratio ◽  
Bead Geometry ◽  
Depth Of Penetration ◽  
Weld Bead Geometry ◽  
Bead Width

The quality of the weld joint is highly influenced by the welding parameters. Hence accurate prediction of weld bead parameters is highly essential to achieve good quality joint. This paper presents development of neural network models for predicting bead parameters such as depth of penetration, bead width and depth to width ratio for AISI 202 grade stainless steel GTAW plates. The use of this series in certain applications ended in failure of the product as there is no adequate level of user knowledge. Hence it becomes imperative to go for detailed investigations on this grade before recommending it for any application. The process parameters chosen for the study are welding current, welding speed, gas flow rate and welding gun angle. The chosen output parameters were depth of penetration, bead width and depth to width ratio. The experiments were conducted based on design of experiments using fractional factorial with 125 runs. Using the experimental data feed forward back propagation neural net work models were developed and trained using Levenberg Marquardt algorithm. The training, learning, performance and transfer functions used are trainlm, learningdm, MSE and tansig respectively. Four networks were developed with four neurons for the input layer, 3 neurons for the output layer and different nodes for the hidden layer. They are 4 – 2 – 3, 4 – 4 – 3, 4 – 8 – 3 and 4 – 9 – 3. It was found that ANN model based on network 4 – 9 – 3 predicted the bead dimensions more accurately than the other networks. The prediction of weld bead geometry parameters helps in identifying the recommended combination of process parameters to achieve good quality joint.

scholarly journals Study of the Impact of the Synergic Line and the Strategy of Conception on Ti-6Al-4V Wire Arc Additive Manufacturing Process (WAAM-CMT)

2021 ◽  
Vol 1016 ◽  
pp. 250-255
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Travel Speed ◽  
Feed Speed ◽  
Thin Walls ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Manufacturing Technologies ◽  
The Impact ◽  
Wire Arc Additive Manufacturing

In additive manufacturing, technologies based on the fusion of a metallic wire using an electric arc represent an interesting alternative to current manufacturing processes, particularly for large metal parts, thanks to higher deposition rates and lower process costs than powder or wire-laser technologies. A versatile 3D printing device using a DED-W Arc (Direct Energy Deposition by wire-arc) station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters and control the geometrical, metallurgical and the mechanical properties of produced parts. In this study, the impact of two different CMT synergic lines on the energetic and geometric behavior of Ti-6Al-4V single deposits is highlighted. These are related to first order parameters: wire feed speed (WFS) and travel speed (TS). The results show difference on energy, geometric of deposits and different deposition regime between these two law with identical process parameters. The second part of this study focuses on the transition from single deposits to walls and blocks. By first choosing the best set of process parameters to make the construction of thin walls (composed of stacked layers), and then the research the optimal horizontal step of deposition (overlapping) for thicker constructions, results obtained made it possible to validate transition from single deposits (1D) to thick walls (3D) without any weld pool collapse or lack of fusion.

Effect of path strategy on residual stress and distortion in laser and cold metal transfer hybrid additive manufacturing

2021 ◽  
pp. 102203
Author(s):  
Runsheng Li ◽  
Guilan Wang ◽  
Xushan Zhao ◽  
Fusheng Dai ◽  
Cheng Huang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Metal Transfer ◽  
Cold Metal Transfer ◽  
Cold Metal
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