scholarly journals Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

2019 ◽  
Vol 3 (2) ◽  
pp. 32 ◽  
Author(s):  
Yuri Yehorov ◽  
Leandro João da Silva ◽  
Américo Scotti
Keyword(s):  
Deposition Time ◽  
Travel Speed ◽  
Production Costs ◽  
Constant Current ◽  
Feed Speed ◽  
Surface Waviness ◽  
Single Pass ◽  
Target Wall ◽  
Wire Feed Speed ◽  
Wire Feed

The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.

Formation and improvement of surface waviness for additive manufacturing 5A06 aluminium alloy component with GTAW system

2018 ◽  
Vol 24 (2) ◽  
pp. 342-350 ◽  
Author(s):  
Haibin Geng ◽  
Jinglong Li ◽  
Jiangtao Xiong ◽  
Xin Lin ◽  
Dan Huang ◽  
...  
Keyword(s):  
Travel Speed ◽  
Feed Speed ◽  
Surface Waviness ◽  
Forming Process ◽  
Line Energy ◽  
Content Type ◽  
Wire Feed Speed ◽  
The Given ◽  
Wire Feed ◽  
Matching Relation

Purpose As known, the wire and arc additive manufacture technique can achieve stable process control, which is represented with periodic surface waviness, when using empirical methods or feedback control system. But it is usually a tedious work to further reduce it using trial and error method. The purpose of this paper is to unveil the formation mechanism of surface waviness and develop a method to diminish it. Design/methodology/approach Two forming mechanisms, wetting and spreading and remelting, are unveiled by cross-section observation. A discriminant is established to differentiate which mechanism is valid to dominate the forming process under the given process parameters. Findings Finally, a theoretical method is developed to optimize surface waviness, even forming a smooth surface by establishing a matching relation between heat input (line energy) and materials input (the ratio of wire feed speed to travel speed). Originality/value Formation mechanisms are revealed by observing cross-section morphology. A discriminant is established to differentiate which mechanism is valid to dominate the forming process under the given process parameters. A mathematical model is developed to optimize surface waviness, even forming a smooth surface through establishing a matching relation between heat input (line energy) and materials input (the ratio of wire feed speed to travel speed).

scholarly journals Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts

2020 ◽  
Vol 321 ◽  
pp. 03002
Author(s):  
A. Ayed ◽  
G. Bras ◽  
H. Bernard ◽  
P. Michaud ◽  
Y. Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Feed Speed ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
Wire Feed Speed ◽  
Manufacturing Techniques ◽  
Parameter Ranges ◽  
Wire Arc Additive Manufacturing ◽  
Wire Feed

Arc-wire or laser-wire additive manufacturing seems promising because it allows large parts to be produced with significant deposition rates (ten times higher than powder bed additive manufacturing), for a lower investment cost. These additive manufacturing techniques are also very interesting for the construction or the repair of parts. A versatile 3D printing device using a Wire Arc Additive Manufacturing (WAAM) station or laser device Wire Laser Additive Manufacturing (WLAM) for melting a filler wire is developed to repair and build large titanium parts. The final objectives of the study are to optimize the process parameters to control the dimensional stability, the metallurgical and mechanical properties of the produced parts. In this paper, an experimental study is carried out to determine the first order process parameter ranges (synergic law, laser power, wire feed speed, travel speed) appropriate for these two techniques, for repair or construction parts on Ti-6 Al-4V.

scholarly journals Additive Manufacturing of Ti6Al4V with Wire Laser Metal Deposition Process

2021 ◽  
Vol 1016 ◽  
pp. 24-29
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Deposition Process ◽  
Travel Speed ◽  
Beam Power ◽  
Feed Speed ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Growth Prospects ◽  
Wire Feed

Additive manufacturing (AM) using wire as an input material is currently in full swing, with very strong growth prospects thanks to the possibility of creating large parts, with high deposition rates, but also a low investment cost compared to the powder bed fusion machines. A versatile 3D printing device using a Direct Energy Deposition Wire-Laser (DED-W Laser) with Precitec Coaxprinter station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters. The geometrical and metallurgical of produced parts are analyzed. In the literature, several authors agree to define wire feed speed, travel speed, and laser beam power as first-order process parameters governing laser-wire deposition. This study shows the relative importance of these parameters taking separately as well as the importance of their sequencing at the start of the process. Titanium deposit are obtained with powers never explored in bibliography (up to 5 kW), and wire feed speed up to 5 m.min-1 with a complete process repeatability.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

Research of Automatic Welding Machine Controlling System Based Single-Chip

2012 ◽  
Vol 214 ◽  
pp. 700-704
Author(s):  
Jin Hu Song
Keyword(s):  
Production Efficiency ◽  
Feed Speed ◽  
Automatic Welding ◽  
Single Chip ◽  
Interface Circuit ◽  
Welding Machine ◽  
Welding Technology ◽  
Controlling System ◽  
Wire Feed Speed ◽  
Wire Feed

In this paper, a scheme for the structure and controlling design of an all-position automatic welding machine is studied, and also the automatic welding systemis explored in depth. In this system, the C8051F020 single chip is used as the controller and the DC servo-motor as the executive component. Through the interface circuit and software program of the single chip, the system can control and harmonize the wire-feed speed as well as the tread and swing of the welding tractor, and can meet the needs of the all-position welding technology, hence realizing the automation of welding, and increasing the welding production efficiency.

Robust Speed Control Algorithm of Welding Wire Feed System Based on the State Space Model

2014 ◽  
Vol 494-495 ◽  
pp. 1358-1363
Author(s):  
Xiu Mei Wu ◽  
Li Min Sha ◽  
Tao Zi Si ◽  
Lei Jiang
Keyword(s):  
Robust Control ◽  
Control Algorithm ◽  
State Space Model ◽  
Feed Speed ◽  
Welding Quality ◽  
Welding Robot ◽  
Welding Wire ◽  
Space Model ◽  
Wire Feed Speed ◽  
Wire Feed

In the modern welding technology of metal materials, the welding robot is a very important factor. And the welding wire feeding device is a very important part of the welding robot. The welding wire feed systems stabilization and reliability is essential for the welding quality. The resistance is caused by the draw of welding wire and other factors, which is highly nonlinear and stochastic. The wire feed rate and welding quality will be severely affected by the resistance. This paper investigates the method controlling the system according to the observations of the resistance, speed and other factors. There are the complex environmental factors in the welding process, such as the strong magnetic field and high current field, which are random. So the robust control algorithm based on the state space model is designed to keep the welding wire feed speed stable under disturbances. The robust control method can improve the speed of response and eliminate the effect of wire feed resistance to the wire feed speed. Even when disturbed, the system can quickly reach a stable wire feed speed.

scholarly journals A Parametric Study of Additive Manufacturing Process: TA6V Laser Wire Metal Deposition

2021 ◽  
pp. 15-20
Author(s):  
Valentine Cazaubon ◽  
Audrey Abi Akle ◽  
Xavier Fischer
Keyword(s):  
Additive Manufacturing ◽  
Laser Power ◽  
Pearson Correlation ◽  
Metal Deposition ◽  
Feed Speed ◽  
New Process ◽  
Wire Feed Speed ◽  
Subtractive Manufacturing ◽  
Working Principle ◽  
Wire Feed

AbstractAdditive Manufacturing has proven to be an economically and industrially attractive process in building or repairing parts. However, the major issue of this new process is to guarantee a mechanical behavior identical to the subtractive manufacturing methodologies. The work, presented in this paper, is centered on the Laser Wire Metal Deposition (LMD-w) method with the metallic alloy TA6V. Its working principle is to fuse a coaxial wire on a substrate with a laser as a heat source. To better understand the interaction between the input parameters (Laser Power, Wire Feed Speed and Tool Speed) and the clad geometry output variables (Height, Width and Contact Angle) and the substrate displacement, we have realized an experimentation. We printed 9 clads according Taguchi’s experimental design. Pearson correlation coefficient and Fisher test performed on the experimental measures showed as main result: Tool Speed is the parameter with the most significant influence on the output variables.

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