Wire-arc additive manufacturing of a novel high-performance Al-Zn-Mg-Cu alloy: Processing, characterization and feasibility demonstration

2020 ◽  
pp. 101663
Author(s):  
Thomas Klein ◽  
Martin Schnall ◽  
Bianca Gomes ◽  
Piotr Warczok ◽  
Dominik Fleischhacker ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Cu Alloy ◽  
Wire Arc Additive Manufacturing

Microstructure and Corrosion Resistance of Ni-Cu Alloy Fabricated through Wire Arc Additive Manufacturing

2021 ◽  
pp. 131262
Author(s):  
A. Rajesh Kannan ◽  
S. Mohan Kumar ◽  
R. Pramod ◽  
N. Siva Shanmugam ◽  
M. Vishnukumar ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Additive Manufacturing ◽  
Cu Alloy ◽  
Wire Arc Additive Manufacturing

scholarly journals Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1610 ◽  
Author(s):  
Paulo J. Morais ◽  
Bianca Gomes ◽  
Pedro Santos ◽  
Manuel Gomes ◽  
Rudolf Gradinger ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
High Performance ◽  
Mechanical Performance ◽  
Fluorescence Analysis ◽  
Cold Metal Transfer ◽  
Direction Parallel ◽  
X Ray ◽  
Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

Wire arc additive manufacturing of Al-Zn-Mg-Cu alloy: Microstructures and mechanical properties

2020 ◽  
Vol 36 ◽  
pp. 101447
Author(s):  
Bolun Dong ◽  
Xiaoyu Cai ◽  
Sanbao Lin ◽  
Xiaolong Li ◽  
Chenglei Fan ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Cu Alloy ◽  
Microstructures And Mechanical Properties ◽  
Wire Arc Additive Manufacturing

scholarly journals Effect of Ultrasonic Vibration and Interpass Temperature on Microstructure and Mechanical Properties of Cu-8Al-2Ni-2Fe-2Mn Alloy Fabricated by Wire Arc Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (2) ◽  
pp. 215
Author(s):  
Wei Chen ◽  
Yuhua Chen ◽  
Timing Zhang ◽  
Taotao Wen ◽  
Zuozhu Yin ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Electron Microscope ◽  
Additive Manufacturing ◽  
Ultrasonic Vibration ◽  
High Performance ◽  
Acoustic Streaming ◽  
Optical Microscope ◽  
Cavitation Effect ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature

A novel ultrasonic vibration assisted (UVA) wire arc additive manufacturing (WAAM) was used to fabricate Cu-8Al-2Ni-2Fe-2Mn alloy in this study. The effect of different interpass temperatures with and without ultrasonic vibration on the microstructural evolution and mechanical properties of the fabricated part were investigated by optical microscope (OM), scanning electron microscope (SEM), transmission electron microscope (TEM), nanoindentation, and mechanical tensile testing. The results showed that reduction of the interpass temperature without UVA treatment cannot prevent the columnar dendrites directionally growing along the deposition direction. Under the UVA treatment, the coarse columnar dendrites were broken at the interpass temperature of 400 °C, and formed a fine cellular structure with an interpass temperature of 100 °C, owing to the acoustic streaming effect and cavitation effect. In addition, globular κII phase was based on Fe3Al and lamellar κIII phase was based on NiAl distributed in the interdendritic region, whereas κIV phase (rich-Fe) were precipitated in the α-Cu matrix. The improvement of microstructural characteristics caused by UVA treatment further improved the tensile properties and nano-hardness of WAAM fabricated parts. Eventually, it is experimentally demonstrated that WAAM fabricated Cu-8Al-2Ni-2Mn-2Fe alloy can obtain high-performance at UVA process under an interpass temperature of 100 °C.

scholarly journals A Multiaxis Tool Path Generation Approach for Thin Wall Structures Made with WAAM

2021 ◽  
Vol 5 (4) ◽  
pp. 128
Author(s):  
Matthieu Rauch ◽  
Jean-Yves Hascoet ◽  
Vincent Querard
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Tool Path ◽  
Tool Path Generation ◽  
Path Generation ◽  
Thin Wall ◽  
Process Data ◽  
Technical Data ◽  
Wall Structures ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) has emerged over the last decade and is dedicated to the realization of high-dimensional parts in various metallic materials. The usual process implementation consists in associating a high-performance welding generator as heat source, a NC controlled 6 or 8 degrees (for example) of freedom robotic arm as motion system and welding wire as feedstock. WAAM toolpath generation methods, although process specific, can be based on similar approaches developed for other processes, such as machining, to integrate the process data into a consistent technical data environment. This paper proposes a generic multiaxis tool path generation approach for thin wall structures made with WAAM. At first, the current technological and scientific challenges associated to CAD/CAM/CNC data chains for WAAM applications are introduced. The focus is on process planning aspects such as non-planar non-parallel slicing approaches and part orientation into the working space, and these are integrated in the proposed method. The interest of variable torch orientation control for complex shapes is proposed, and then, a new intersection crossing tool path method based on Design For Additive Manufacturing considerations is detailed. Eventually, two industrial use cases are introduced to highlight the interest of this approach for realizing large components.

scholarly journals Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

2021 ◽  
Vol 11 (10) ◽  
pp. 4694
Author(s):  
Christian Wacker ◽  
Markus Köhler ◽  
Martin David ◽  
Franziska Aschersleben ◽  
Felix Gabriel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
High Energy ◽  
Welding Distortion ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Industrial Use ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

Sign in / Sign up

Export Citation Format

Share Document