Wire arc additive manufacturing of thin-wall low-carbon steel parts: Microstructure and mechanical properties

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040154
Author(s):  
Van Thao Le ◽  
Tien Long Banh ◽  
Duc Toan Nguyen ◽  
Van Tao Le
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Heat Input ◽  
Low Carbon Steel ◽  
Production Costs ◽  
High Deposition Rate ◽  
Thin Wall ◽  
Low Carbon ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) has received much attention for manufacturing metal parts with medium and large dimensions because of its high deposition rate and low production costs. In this study, the effects of the heat input on the microstructure formation of thin-wall low-carbon steel parts built by a WAAM process were addressed. The mechanical properties of built materials were also studied. The results indicate that the heat input significantly influences on the shape of built thin walls, but has slight effects on the microstructure evolution of built materials. The WAAM thin-wall low-carbon steel presents suitable microstructures and good tensile strengths (YS: 320 – 362 MPa, UTS: 429 – 479 MPa) that are adequate with industrial applications.

scholarly journals EFFECTS OF WELDING CURRENT ON THE SHAPE AND MICROSTRUCTURE FORMATION OF THIN-WALLED LOW-CARBON PARTS BUILT BY WIRE ARC ADDITIVE MANUFACTURING

2020 ◽  
Vol 58 (4) ◽  
pp. 461
Author(s):  
Van Thao Le ◽  
Quang Huy Hoang ◽  
Van Chau Tran ◽  
Dinh Si Mai ◽  
Duc Manh Dinh ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Low Carbon Steel ◽  
Welding Current ◽  
Welding Parameters ◽  
Low Carbon ◽  
Microstructure Formation ◽  
Thin Walled ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is nowadays gaining much attention from both the academic and industrial sectors for the manufacture of medium and large dimension metal parts because of its high deposition rate and low costs of equipment investment. In the literature, WAAM has been extensively investigated in terms of the shape and dimension accuracy of built parts. However, limited research has focused on the effects of welding parameters on the microstructural characteristics of parts manufactured by this process. In this paper, the effects of welding current in the WAAM process on the shape and the microstructure formation of built thin-walled low-carbon steel components were studied. For this purpose, the thin-walled low-carbon steel samples were built layer-by-layer on the substrates by using an industrial gas metal arc welding robot with different levels of welding current. The shape, microstructures and mechanical properties of built samples were then analyzed. The obtained results show that the welding current plays an important role in the shape stability, but does not significantly influence on the microstructure formation of built thin-walled samples. The increase of the welding current only leads to coarser grain size and resulting in decreasing the hardness of built materials in each zone of the built sample. The mechanical properties (hardness and tensile properties) of the WAAM-built thin-walled low-carbon steel parts are also comparable to those of wrought low-carbon steel, and to be adequate with real 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 Environmental Behavior of Low Carbon Steel Produced by a Wire Arc Additive Manufacturing Process

Metals ◽  
2019 ◽  
Vol 9 (8) ◽  
pp. 888 ◽  
Author(s):  
Ron ◽  
Levy ◽  
Dolev ◽  
Leon ◽  
Shirizly ◽  
...  
Keyword(s):  
Corrosion Resistance ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Stress Corrosion ◽  
Environmental Behavior ◽  
Low Carbon Steel ◽  
General Corrosion ◽  
Low Carbon ◽  
Corrosion Performance ◽  
Wire Arc Additive Manufacturing

: Current additive manufacturing (AM) processes are mainly focused on powder bed technologies, such as electron beam melting (EBM) and selective laser melting (SLM). However, the main disadvantages of such techniques are related to the high cost of metal powder, the degree of energy consumption, and the sizes of the components, that are limited by the size of the printing cell. The aim of the present study was to evaluate the environmental behavior of low carbon steel (ER70S-6) produced by a relatively inexpensive AM process using wire feed arc welding. The mechanical properties were examined by tension testing and hardness measurements, while microstructure was assessed by scanning electron microscopy and X-ray diffraction analysis. General corrosion performance was evaluated by salt spray testing, immersion testing, potentiodynamic polarization analysis, and electrochemical impedance spectroscopy. Stress corrosion performance was characterized in terms of slow strain rate testing (SSRT). All corrosion tests were carried out in 3.5% NaCl solution at room temperature. The results indicated that the general corrosion resistance of wire arc additive manufacturing (WAAM) samples were quite similar to those of the counterpart ST-37 steel and the stress corrosion resistance of both alloys was adequate. Altogether, it was clearly evident that the WAAM process did not encounter any deterioration in corrosion performance compared to its conventional wrought alloy counterpart.

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.

Microstructure and mechanical properties of low-carbon steel fabricated by electron-beam additive manufacturing

2021 ◽  
Vol 11 (4) ◽  
pp. 427-432
Author(s):  
Elena Astafurova ◽  
Evgeny Melnikov ◽  
Sergey Astafurov ◽  
Marina Panchenko ◽  
Kseniya Reunova ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Low Carbon Steel ◽  
Low Carbon ◽  
Microstructure And Mechanical Properties

Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire + arc additive manufacturing

2019 ◽  
Vol 26 (3) ◽  
pp. 519-530 ◽  
Author(s):  
Md. Rumman Ul Ahsan ◽  
Ali Newaz Mohammad Tanvir ◽  
Taylor Ross ◽  
Ahmed Elsawy ◽  
Min-Suk Oh ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Low Carbon Steel ◽  
Hardness Profile ◽  
Sudden Increase ◽  
Low Carbon ◽  
Content Type ◽  
Multiple Materials ◽  
Wire Arc Additive Manufacturing

Purpose Wire + arc additive manufacturing (WAAM) uses existing welding technology to make a part from metal deposited in an almost net shape. WAAM is flexible in that it can use multiple materials successively or simultaneously during the manufacturing of a single component. Design/methodology/approach In this work, a gas metal arc welding (GMAW) based wire + arc additive manufacturing (WAAM) system has been developed to use two material successively and fabricate bimetallic additively manufactured structure (BAMS) of low carbon steel and AISI 316L stainless steel (SS). Findings The interface shows two distinctive zones of LCS and SS deposits without any weld defects. The hardness profile shows a sudden increase of hardness at the interface, which is attributed to the migration of chromium from the SS. The tensile test results show that the bimetallic specimens failed at the LCS side, as LCS has lower strength of the materials used. Originality/value The microstructural features and mechanical properties are studied in-depth with special emphasis on the bimetallic interface.

scholarly journals Structure of a 3D frame-bridge NiTi sample deposited on a low carbon steel substrate by wire arc additive manufacturing

2020 ◽  
Vol 10 (4) ◽  
pp. 496-500
Author(s):  
Natalia Resnina ◽  
I.A. Palani ◽  
Pavel Liulchak ◽  
Sergey Belyaev ◽  
S.S. Mani Prabu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Steel ◽  
Steel Substrate ◽  
Low Carbon Steel ◽  
Low Carbon ◽  
Wire Arc Additive Manufacturing
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