scholarly journals Hot-wire arc additive manufacturing of aluminum alloy with reduced porosity and high deposition rate

2021 ◽  
Vol 199 ◽  
pp. 109370
Author(s):  
Rui Fu ◽  
Shuiyuan Tang ◽  
Jiping Lu ◽  
Yinan Cui ◽  
Zixiang Li ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Deposition Rate ◽  
High Deposition Rate ◽  
Hot Wire ◽  
Wire Arc Additive Manufacturing

scholarly journals A Review of Aluminum Alloy Fabricated by Different Processes of Wire Arc Additive Manufacturing

2021 ◽  
Vol 27 (1) ◽  
pp. 18-26
Author(s):  
Zeli WANG ◽  
Yuanbin ZHANG
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Topological Optimization ◽  
Utilization Rate ◽  
Future Research ◽  
General Tendency ◽  
High Deposition Rate ◽  
Microstructure And Mechanical Properties ◽  
Wire Arc Additive Manufacturing

Due to the advantages of high deposition rate, low equipment cost and high material utilization rate, aluminum alloy fabricated by wire arc additive manufacturing (WAAM) has been widely concerned by scholars and scientific institutions. This article reviews the features of aluminum alloy fabricated by different WAAM processes (GMAW-based, GTAW-based, CMT-based, PAW-based). Research status of the porosity, dimensional accuracy, microstructure and mechanical properties of aluminum alloy in different process is analyzed. General tendency of microstructure and mechanical properties were discussed, and suggestions for the future research direction were put forward including mandatory constraint on molten pool and structural topological optimization.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

Experimental investigation of laser hot-wire cladding

2015 ◽  
Vol 231 (6) ◽  
pp. 1007-1020 ◽  
Author(s):  
Shuang Liu ◽  
Wei Liu ◽  
Radovan Kovacevic
Keyword(s):  
Deposition Rate ◽  
Laser Power ◽  
Laser Scanning ◽  
Feeding Rate ◽  
Inconel 625 ◽  
Small Range ◽  
High Deposition Rate ◽  
Hot Wire ◽  
Cold Wire ◽  
Wire Feeding

Laser cladding by cold-wire feeding is known as an efficient cladding method due to its advantages, such as near 100% material utilization, high deposition rate, and flexible adaptation to the cladding position. However, it has very stringent requirements on the operative conditions, such as a small range of wire feeding rate and precise wire feeding position. The aim of this work was to investigate the laser hot-wire cladding technique, which improved the productivity and stability of the process significantly with respect to laser cold-wire cladding. The external preheating of the filler wire resulted in reduction in required laser power, a low dilution, and a higher deposition rate. A comparison was made between laser cold-wire cladding and laser hot-wire cladding of Inconel 625 on mild steel, with respect to the clad characteristics, microstructure, and hardness. An optimization of the main processing parameters in laser hot-wire cladding, such as the laser power, laser spot size, laser scanning speed, wire feeding orientation and position, wire preheating voltage, and wire feeding rate, was performed. The optimal parameters were used to create a multi-track deposit.

scholarly journals Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 892 ◽  
Author(s):  
Eider Aldalur ◽  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Jon Bilbao ◽  
Aitzol Lamikiz
Keyword(s):  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Low Carbon Steel ◽  
Utilization Rate ◽  
High Deposition Rate ◽  
Low Carbon ◽  
Metal Arc Welding ◽  
Geometric Precision ◽  
Directed Energy ◽  
Wire Arc Additive Manufacturing

Additive manufacturing has gained relevance in recent decades as an alternative to the manufacture of metal parts. Among the additive technologies, those that are classified as Directed Energy Deposition (DED) are characterized by their high deposition rate, noticeably, Wire Arc Additive Manufacturing (WAAM). However, having the inability to produce parts with acceptable final surface quality and high geometric precision is to be considered an important disadvantage in this process. In this paper, different torch trajectory strategies (oscillatory motion and overlap) in the fabrication of low carbon steel walls will be compared using Gas Metal Arc Welding (GMAW)-based WAAM technology. The comparison is done with a study of the mechanical and microstructural characteristics of the produced walls and finally, addressing the productivity obtained utilizing each strategy. The oscillation strategy shows better results, regarding the utilization rate of deposited material and the flatness of the upper surface, this being advantageous for subsequent machining steps.

Comparison of Hardness and Microstructures Produced Using GMAW and Hot-Wire TIG Mechanized Welding of High Strength Steels

2014 ◽  
Author(s):  
A. R. H. Midawi ◽  
E. B. F. Santos ◽  
A. P. Gerlich ◽  
R. Pistor ◽  
M. Haghshenas
Keyword(s):  
Weld Metal ◽  
Deposition Rate ◽  
Heat Input ◽  
Gas Metal Arc Welding ◽  
High Strength Steels ◽  
Travel Speed ◽  
Pressure Vessels ◽  
High Deposition Rate ◽  
Hot Wire ◽  
Wire Feed

For high productivity weld fabrication, gas metal arc welding (GMAW) is typically used since it offers a combination of high deposition rate and travel speed. Recent advances in power supply technologies have increased the deposition rates in hot-wire tungsten inert gas (HW-TIG) welding, such that it is possible to achieve parameters which may be comparable to those used in GMAW for pressure vessels and some pipeline applications. However, these two processes have drastically different deposition efficiencies and heat input characteristics. The purpose of the present study is to examine GMAW and HW-TIG bead-on-plate deposits in terms of mechanical properties, deposition rate, and heat affected zone (HAZ) thermal cycles when identical travel speed and wire feed speeds are applied with a ER90S-G filler metal. The results demonstrate that HW-TIG can be applied with comparable travel and wire feed speeds to GMAW, while providing a more uniform weld bead appearance. Based on weld metal microhardness values, it is suggested the effective heat input is lower in HW-TIG compared to GMAW, since the average hardness of the weld metal is slightly higher.

scholarly journals Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

2021 ◽  
pp. 61-66
Author(s):  
Akram Chergui ◽  
Nicolas Beraud ◽  
Frédéric Vignat ◽  
François Villeneuve
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Low Cost ◽  
Source Model ◽  
Metal Deposition ◽  
High Deposition Rate ◽  
Element Technique ◽  
Metallic Parts ◽  
Wire Arc Additive Manufacturing

AbstractWire arc additive manufacturing allows the production of metallic parts by depositing beads of weld metal using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this work, a new finite element technique is proposed in order to model metal deposition in WAAM process. This technique allows to gradually construct the mesh representing the deposited regions along the deposition path. The heat source model proposed by Goldak is adapted and combined with the proposed metal deposition technique taking into account the energy distribution between filler material and the molten pool. The effectiveness of the proposed method is validated by series of experiments, of which an example is detailed in this paper.

scholarly journals Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5370
Author(s):  
Geir Langelandsvik ◽  
Odd M. Akselsen ◽  
Trond Furu ◽  
Hans J. Roven
Keyword(s):  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Alloy Composition ◽  
Layer By Layer ◽  
Alloy Development ◽  
And Performance ◽  
Crack Susceptibility ◽  
Wire Arc Additive Manufacturing ◽  
Further Development ◽  
Complex Parts

Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

scholarly journals Vision-Based Melt Pool Monitoring for Wire-Arc Additive Manufacturing Using Deep Learning Method

2021 ◽  
Author(s):  
Chunyang Xia ◽  
Zengxi Pan ◽  
Yuxing Li ◽  
Huijun Li
Keyword(s):  
Deep Learning ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Deposition Process ◽  
Utilization Rate ◽  
High Deposition Rate ◽  
Promising Alternative ◽  
Visual Monitoring ◽  
Melt Pool ◽  
Wire Arc Additive Manufacturing

Abstract Wire-arc additive manufacturing (WAAM) technology has been widely recognized as a promising alternative for fabricating large-scale components, due to its advantages of high deposition rate and high material utilization rate. However, some anomalies may occur during the deposition process, such as humping, spattering, and robot suspend. this study proposed to apply Deep Learning in the visual monitoring to diagnose different anomalies during WAAM process. The melt pool images of different anomalies were collected for training and validation by a visual monitoring system. The classification performance of several representative CNN architectures, including ResNet, EfficientNet, VGG-16 and GoogLeNet, were investigated and compared. The classification accuracy of 97.62%, 97.45%, 97.15% and 97.25% was achieved by each model. The results proved that the CNN models are effective in classifying different types of melt pool images of WAAM. Our study is applicable beyond WAAM and should benefit other additive manufacturing or arc welding techniques.

Sign in / Sign up

Export Citation Format

Share Document