Investigations on Process Parameters of Wire Arc Additive Manufacturing (WAAM): A Review

2021 ◽  
pp. 845-853
Author(s):  
Mayank Chaurasia ◽  
Manoj Kumar Sinha
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Wire Arc Additive Manufacturing

scholarly journals Optimization of Cold Metal Transfer-Based Wire Arc Additive Manufacturing Processes Using Gaussian Process Regression

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 461
Author(s):  
Seung Hwan Lee
Keyword(s):  
Additive Manufacturing ◽  
Gaussian Process ◽  
Process Parameters ◽  
Gaussian Process Regression ◽  
Effective Area ◽  
Raw Material ◽  
Cold Metal Transfer ◽  
High Productivity ◽  
Multiple Variables ◽  
Wire Arc Additive Manufacturing

Wire and arc additive manufacturing (WAAM) is among the most promising additive manufacturing techniques for metals because it yields high productivity at low raw material costs. However, additional post-processing is required to remove redundant surface material from components manufactured by the WAAM process, and thus the productivity decreases. To increase productivity, multi-variable process parameters need to be optimized, including thermo-mechanical effects caused by high deposition rates. When the process is modeled, deposit shape and productivity are challenging to quantify due to uncertainty in multiple variables of the complicated WAAM process. Therefore, we modeled the WAAM process parameters, including uncertainties, using a Gaussian process regression (GPR) method, thus allowing us to develop a WAAM optimization model to improve both productivity and the quality of the deposit shape. The accuracy of the optimized output was verified through a close agreement with experimental values. The optimized deposited material had a wide effective area ratio, small height differences, and near 90° deposition angle, highlighting the usefulness of the GPR model approach to deposit nearly ideal material shapes.

scholarly journals Selection of Optimal Process Parameters for Wire Arc Additive Manufacturing

Procedia CIRP ◽  
2017 ◽  
Vol 62 ◽  
pp. 470-474 ◽  
Author(s):  
Mariacira Liberini ◽  
Antonello Astarita ◽  
Gianni Campatelli ◽  
Antonio Scippa ◽  
Filippo Montevecchi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Optimal Process ◽  
Wire Arc Additive Manufacturing ◽  
Selection Of

scholarly journals Wire Arc Additive Manufacturing with Novel Al-Mg-Si Filler Wire—Assessment of Weld Quality and Mechanical Properties

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1243
Author(s):  
René Winterkorn ◽  
Andreas Pittner ◽  
Michael Rethmeier
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Treatment Strategies ◽  
Base Material ◽  
High Strength ◽  
Solidification Cracking ◽  
Filler Wire ◽  
Equiaxed Grains ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing enables the production of near-net shape large-volume metallic components leveraging an established industrial base of welding and cladding technology and adapting it for layer-wise material deposition. However, the complex relationship between the process parameters and resulting mechanical properties of the components still remains challenging. In case of high-strength Al-Mg-Si aluminum alloys, no commercial filler wires are yet available due the high susceptibility of solidification cracking as well as the necessary efforts to obtain acceptable mechanical properties. To address this need, we evaluated a novel filler wire based on AlMg0.7Si doped with a Ti5B1 master alloy to foster fine equiaxed grains within the deposited metal. The correlation between the process parameters and component quality was examined by analyzing the size and distribution of pores as well as the grain morphology. Furthermore, we evaluated the influence of different post-weld heat treatment strategies to achieve mechanical properties corresponding to the reference wrought material. We demonstrated that fine equiaxed grains in the weld metal reduced the susceptibility of solidification cracking significantly. The novel AlMg0.7Si-TiB (S Al 6063-TiB) filler wire facilitated wire arc additive manufacturing of high-strength aluminum components with mechanical properties that were almost as superior as the corresponding wrought base material.

Wire Arc Additive Manufacturing of Stainless Steels: A Review

2020 ◽  
Vol 10 (5) ◽  
pp. 1563 ◽  
Author(s):  
Wanwan Jin ◽  
Chaoqun Zhang ◽  
Shuoya Jin ◽  
Yingtao Tian ◽  
Daniel Wellmann ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Residual Stress ◽  
Stainless Steel ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Stainless Steels ◽  
Heat Treatments ◽  
Physical Metallurgy ◽  
Deposition Rates ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) has been considered as a promising technology for the production of large metallic structures with high deposition rates and low cost. Stainless steels are widely applied due to good mechanical properties and excellent corrosion resistance. This paper reviews the current status of stainless steel WAAM, covering the microstructure, mechanical properties, and defects related to different stainless steels and process parameters. Residual stress and distortion of the WAAM manufactured components are discussed. Specific WAAM techniques, material compositions, process parameters, shielding gas composition, post heat treatments, microstructure, and defects can significantly influence the mechanical properties of WAAM stainless steels. To achieve high quality WAAM stainless steel parts, there is still a strong need to further study the underlying physical metallurgy mechanisms of the WAAM process and post heat treatments to optimize the WAAM and heat treatment parameters and thus control the microstructure. WAAM samples often show considerable anisotropy both in microstructure and mechanical properties. The new in-situ rolling + WAAM process is very effective in reducing the anisotropy, which also can reduce the residual stress and distortion. For future industrial applications, fatigue properties, and corrosion behaviors of WAAMed stainless steels need to be deeply studied in the future. Additionally, further efforts should be made to improve the WAAM process to achieve faster deposition rates and better-quality control.

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.

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