scholarly journals Influence of Interpass Temperature on Wire Arc Additive Manufacturing (WAAM) of Aluminium Alloy Components

2019 ◽  
Vol 269 ◽  
pp. 05001 ◽  
Author(s):  
Karan Derekar ◽  
Jonathan Lawrence ◽  
Geoff Melton ◽  
Adrian Addison ◽  
Xiang Zhang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Tensile Properties ◽  
Deposition Pattern ◽  
Formed Product ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature ◽  
Temperature Sample ◽  
Better Than

Wire arc additive manufacturing (WAAM) technique has revealed the potential of replacing existing aerospace industry parts manufactured by traditional manufacturing routes. The reduced mechanical properties compared to wrought products, the porosity formation, and solidification cracking are the prime constraints that are restricting wide-spread applications of WAAM products using aluminium alloys. An interpass temperature is less studied in robotic WAAM and is the vital aspect affecting the properties of a formed product. This paper highlights the effects of change in interpass temperature on porosity content and mechanical properties of WAAM parts prepared using DC pulsed GMAW process, with 5356 aluminium consumable wire. The samples prepared with different interpass temperatures were studied for the distribution of pores with the help of computed tomography radiography (CT radiography) technique. A WAAM sample produced with higher interpass temperature revealed 10.41% less porosity than the sample prepared with lower interpass temperature. The pores with size less than 0.15mm3 were contributing over 95% of the overall porosity content. Additionally, on a volumetric scale, small pores (<0.15mm3) in the higher interpass temperature sample contributed 81.47% of overall volume of pores whereas only 67.92% volume was occupied in lower interpass temperature sample with same sized pores. The different solidification rates believed to have influence on the hydrogen evolution mechanism. Tensile properties of higher interpass temperature sample were comparatively better than lower interpass temperature sample. For the deposition pattern used in this study, horizontal specimens were superior to vertical specimens in tensile properties.

scholarly journals Mechanical properties of wire and arc additively manufactured high-strength steel structures

2021 ◽  
Author(s):  
Johanna Müller ◽  
Jonas Hensel ◽  
Klaus Dilger
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Yield Strength ◽  
High Strength Steel ◽  
Energy Input ◽  
High Strength ◽  
Accelerated Cooling ◽  
Active Cooling ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature

AbstractAdditive manufacturing with steel opens up new possibilities for the construction sector. Especially direct energy deposition processes like DED-arc, also known as wire arc additive manufacturing (WAAM), is capable of manufacturing large structures with a high degree of geometric freedom, which makes the process suitable for the manufacturing of force flow-optimized steel nodes and spaceframes. By the use of high strength steel, the manufacturing times can be reduced since less material needs to be deposited. To keep the advantages of the high strength steel, the effect of thermal cycling during WAAM needs to be understood, since it influences the phase transformation, the resulting microstructure, and hence the mechanical properties of the material. In this study, the influences of energy input, interpass temperature, and cooling rate were investigated by welding thin walled samples. From each sample, microsections were analyzed, and tensile test and Charpy-V specimens were extracted and tested. The specimens with an interpass temperature of 200 °C, low energy input and applied active cooling showed a tensile strength of ~ 860–900 MPa, a yield strength of 700–780 MPa, and an elongation at fracture between 17 and 22%. The results showed the formation of martensite for specimens with high interpass temperatures which led to low yield and high tensile strengths (Rp0.2 = 520–590 MPa, Rm = 780–940 MPa) for the specimens without active cooling. At low interpass temperatures, the increase of the energy input led to a decrease of the tensile and the yield strength while the elongation at fracture as well as the Charpy impact energy increased. The formation of upper bainite due to the higher energy input can be avoided by accelerated cooling while martensite caused by high interpass temperatures need to be counteracted by heat treatment.

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 On the Effect of Heat Input and Interpass Temperature on the Performance of Inconel 625 Alloy Deposited Using Wire Arc Additive Manufacturing–Cold Metal Transfer Process

Metals ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 46
Author(s):  
Chengxun Zhang ◽  
Zhijun Qiu ◽  
Hanliang Zhu ◽  
Zhiyang Wang ◽  
Ondrej Muránsky ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Inconel 625 ◽  
Heat Accumulation ◽  
Cold Metal Transfer ◽  
Inconel 625 Alloy ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature

Relatively high heat input and heat accumulation are treated as critical challenges to affect the qualities and performances of components fabricated by wire arc additive manufacturing (WAAM). In this study, various heat inputs, namely 276, 552 and 828 J/mm, were performed to fabricate three thin-wall Inconel 625 structures by cold metal transfer (CMT)-based WAAM, respectively, and active interpass cooling was conducted to limit heat accumulation. The macrostructure, microstructure and mechanical properties of the produced components by CMT were investigated. It was found that the increased heat input can deteriorate surface roughness, and the size of dendrite arm spacing increases with increasing heat input, thus leading to the deterioration of mechanical properties. Lower heat input and application of active interpass cooling can be an effective method to refine microstructure and reduce anisotropy. This study enhances the understanding of interpass temperature control and the effectiveness of heat inputs for Inconel 625 alloy by WAAM. It also provides a valuable in situ process for microstructure and mechanical properties’ refinement of WAAM-fabricated alloys and the control of heat accumulation for the fabrication of large-sized structures for future practical applications.

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.

scholarly journals Effect of Filler Metal Type on Microstructure and Mechanical Properties of Fabricated NiAl Bronze Alloy Using Wire Arc Additive Manufacturing System

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 513
Author(s):  
Jae Won Kim ◽  
Jae-Deuk Kim ◽  
Jooyoung Cheon ◽  
Changwook Ji
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Filler Metal ◽  
Gas Metal Arc Welding ◽  
Metal Wire ◽  
Cold Metal Transfer ◽  
Metal Type ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

This study observed the effect of filler metal type on mechanical properties of NAB (NiAl-bronze) material fabricated using wire arc additive manufacturing (WAAM) technology. The selection of filler metal type is must consider the field condition, mechanical properties required by customers, and economics. This study analyzed the bead shape for representative two kind of filler metal types use to maintenance and fabricated a two-dimensional bulk NAB material. The cold metal transfer (CMT) mode of gas metal arc welding (GMAW) was used. For a comparison of mechanical properties, the study obtained three specimens per welding direction from the fabricated bulk NAB material. In the tensile test, the NAB material deposited using filler metal wire A showed higher tensile strength and lower elongation (approx. +71 MPa yield strength, +107.1 MPa ultimate tensile strength, −12.4% elongation) than that deposited with filler metal wire B. The reason is that, a mixture of tangled fine α platelets and dense lamellar eutectoid α + κIII structure with β´ phases was observed in the wall made with filler metal wire A. On the other hand, the wall made with filler metal wire B was dominated by coarse α phases and lamellar eutectoid α + κIII structure in between.

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