scholarly journals A Methodology to Parameterize Wire + Arc Additive Manufacturing: A Case Study for Wall Quality Analysis

2020 ◽  
Vol 4 (1) ◽  
pp. 14 ◽  
Author(s):  
Shubham Dahat ◽  
Kjell Hurtig ◽  
Joel Andersson ◽  
Americo Scotti
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Set Covering ◽  
Quality Analysis ◽  
Layer Width ◽  
Multiple Parameters ◽  
Operating Limits ◽  
Wire Arc Additive Manufacturing ◽  
Effective Layer

The objective of this work was the development of a methodology to parametrize wire + arc additive manufacturing (WAAM), aiming dimension repeatability, and tolerances. Parametrization of WAAM is a difficult task, because multiple parameters are involved and parameters are inter-dependent on each other, making overall process complex. An approach to study WAAM would be through operational maps. The choice of current (Im) and travel speed (TS) for the desirable layer width (LW) determines a parametrization that leads to either more material or less material to be removed in post-operations, which is case study chosen for this work. The work development had four stages. First stage, named ‘mock design’, had the objective of visualizing the expected map and reduce further number of experiments. At the second stage, ‘pre-requisite for realistic operational map’, the objective was to determine the operating limits of TS and Im with the chosen consumables and equipment. Within the ‘realistic operational map’ stage, a design for the experiments was applied to cover a parametric area (working envelope) already defined in the previous stage and long and tall walls were additively manufactured. Actual values of LW (external and effective layer width) were measured and an actual operating envelope was reached. According to the geometry-oriented case study, a surface waviness index (SWindex) was defined, determined, and overlapped in the envelope. It was observed that the walls with parameters near the travel speed limits presented higher SWindex. This operational map was further validated (fourth stage) by selecting a target LW and finding corresponding three parametric set (covering the whole range of operational map) to produce walls on which geometry characterization was carried out. After geometry characterization, obtained LW was compared with the target LW (the maximum values were very tied, with deviations from +0.3 to 0.5 mm), with a SWindex deviation at the order of 0.05. Both results evidence high reproductivity of the process, validating the proposed methodology to parametrize WAAM.

Model predictive control of layer width in wire arc additive manufacturing

2020 ◽  
Vol 58 ◽  
pp. 179-186
Author(s):  
Chunyang Xia ◽  
Zengxi Pan ◽  
Shiyu Zhang ◽  
Joseph Polden ◽  
Long Wang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Model Predictive Control ◽  
Predictive Control ◽  
Layer Width ◽  
Wire Arc Additive Manufacturing

scholarly journals Effects of Solution Treatment on Laser Welding of Ti–6Al–4V Alloy Plate Produced through Wire Arc Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1310
Author(s):  
Mingfang Xu ◽  
Yuhua Chen ◽  
Timing Zhang ◽  
Huaibo Deng ◽  
Di Ji
Keyword(s):  
Tensile Strength ◽  
Additive Manufacturing ◽  
Laser Beam Welding ◽  
Solution Treatment ◽  
High Strength ◽  
Travel Speed ◽  
Alloy Plate ◽  
Weave Structure ◽  
The Difference ◽  
Wire Arc Additive Manufacturing

Laser beam welding (LBW) had been successfully applied to the welding of Ti–6Al–4V plates by wire arc additive manufacturing. The effects of solution treatment on microstructure, tensile properties, and microhardness after LBW in different deposition directions were studied. When the wire speeding was 3 m/min and travel speed was 0.36 m/min, the difference in mechanical properties was related to the anisotropy of the microstructure. The long columnar grain along the building direction could provide an α path with a large aspect ratio and high elongation. More grain boundaries are present along the scanning direction than in others, showing high strength. The microstructure of the as-deposited condition mainly consists of coarse prior-β grains, partial basket-weave structure, and numerous martensite α′ phase. In LBW without solution treatment, the microstructure of the welds mainly consists of a large amount of martensite α′ and a small amount of basket-weave structure. The weld had high strength and hardness. The tensile strength was between 930 and 970 MPa. The hardness was between 415 and 456 HV. The elongation ranged from 5% to 7%. Afterwards, the temperature was maintained at 870 °C for 2 h, cooled to 600 °C in the furnace for 1 h, and finally air cooled to room temperature. The martensite α′ was almost completely transformed into platelet α. The microstructure of the welds mainly consists of partial β grains, thimbleful martensite α′, and a large of α path. The strength and hardness of the welds were reduced. The tensile strength is between 910 and 950 MPa. The hardness was between 398 and 445 HV. However, the elongation was significantly improved, and the elongation ranged from 10% to 12%.

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.

Direct fabrication of inclined thin-walled parts by exploiting inherent overhanging capability of CMT process

2019 ◽  
Vol 26 (3) ◽  
pp. 499-508
Author(s):  
Yun Zhao ◽  
Fang Li ◽  
Shujun Chen ◽  
Zhenyang Lu
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
Travel Speed ◽  
Statistical Prediction ◽  
Feed Speed ◽  
Auxiliary Equipment ◽  
Content Type ◽  
Geometrical Features ◽  
Thin Walled ◽  
Wire Arc Additive Manufacturing

Purpose The purpose of this paper is to develop a build strategy for inclined thin-walled parts by exploiting the inherent overhanging capability of the cold metal transfer (CMT) process, which release wire-arc additive manufacturing from tedious programming work and restriction of producible size of parts. Design/methodology/approach Inclined thin-walled parts were fabricated with vertically placed welding torch free from any auxiliary equipment. The inclined features were defined and analyzed based on the geometrical model of inclined parts. A statistical prediction model was developed to describe the dependence of inclined geometrical features on process variables. Based on these models, a build strategy was proposed to plan tool path and output process parameters. After that, the flow work was illustrated by fabricating a vase part. Findings The formation mechanism and regulation of inclined geometrical features were revealed by conducting experimental trials. The inclined angle can be significantly increased along with the travel speed and offset distance, whereas the wall width is mainly dependent on the ratio of wire feed speed to travel speed. In contrast to other welding process, CMT has a stronger overhanging capability, which provides the possibility to fabricate parts with large overhanging features directly with high forming accuracy. Originality/value This paper describes a novel build strategy for inclined thin-walled parts free from any auxiliary equipment. With the proposed strategy, a complex structural component can be deposited directly in the rectangular coordinates additive manufacturing system, indicating infinite possibilities on the producible size of the parts. Moreover, equipment requirements and tedious program work can also be significantly reduced.

scholarly journals Study of the Impact of the Synergic Line and the Strategy of Conception on Ti-6Al-4V Wire Arc Additive Manufacturing Process (WAAM-CMT)

2021 ◽  
Vol 1016 ◽  
pp. 250-255
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Travel Speed ◽  
Feed Speed ◽  
Thin Walls ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Manufacturing Technologies ◽  
The Impact ◽  
Wire Arc Additive Manufacturing

In additive manufacturing, technologies based on the fusion of a metallic wire using an electric arc represent an interesting alternative to current manufacturing processes, particularly for large metal parts, thanks to higher deposition rates and lower process costs than powder or wire-laser technologies. A versatile 3D printing device using a DED-W Arc (Direct Energy Deposition by wire-arc) station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters and control the geometrical, metallurgical and the mechanical properties of produced parts. In this study, the impact of two different CMT synergic lines on the energetic and geometric behavior of Ti-6Al-4V single deposits is highlighted. These are related to first order parameters: wire feed speed (WFS) and travel speed (TS). The results show difference on energy, geometric of deposits and different deposition regime between these two law with identical process parameters. The second part of this study focuses on the transition from single deposits to walls and blocks. By first choosing the best set of process parameters to make the construction of thin walls (composed of stacked layers), and then the research the optimal horizontal step of deposition (overlapping) for thicker constructions, results obtained made it possible to validate transition from single deposits (1D) to thick walls (3D) without any weld pool collapse or lack of fusion.

scholarly journals Prediction of welding bead geometry for wire arc additive manufacturing of SS308l walls using response surface methodology

2020 ◽  
Vol 71 (4) ◽  
pp. 431-443 ◽  
Author(s):  
Le Van Thao ◽  
Mai Dinh Si ◽  
Doan Tat Khoa ◽  
Hoang Quang Huy
Keyword(s):  
Response Surface Methodology ◽  
Additive Manufacturing ◽  
Response Surface ◽  
Design Method ◽  
Welding Current ◽  
Travel Speed ◽  
Bead Geometry ◽  
Bead Width ◽  
Bead Height ◽  
Wire Arc Additive Manufacturing

In the wire arc additive manufacturing (WAAM) process, the geometry of single welding beads has significant effects on the stability process and the final quality and shape of manufactured parts. In this paper, the geometry of single welding beads of 308L stainless steel was predicted as functions of process parameters (i.e. welding current I, voltage U, and travel speed v) by using the response surface methodology (RSM). A set of experimental runs was carried out by using the Box-Behnken design method. The adequacy of the developed models was assessed by using an analysis of variance (ANOVA). The results indicate that the RSM allows the predictive models of bead width (BW) and bead height (BH) to be developed with a high accuracy: R2-values of BW and BH are 99.01% and 99.61%, respectively. The errors between the predicted and experimental values for the confirmatory experiments are also lower than 5% that again confirms the adequacy of the developed models. These developed models can efficiently be used to predict the desirable geometry of welding beads for the adaptive slicing principle in WAAM.

scholarly journals Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 5077
Author(s):  
Artem Voropaev ◽  
Rudolf Korsmik ◽  
Igor Tsibulsky
Keyword(s):  
Additive Manufacturing ◽  
Short Circuit ◽  
Unit Length ◽  
Welding Current ◽  
Travel Speed ◽  
Welding Torch ◽  
Specialized Equipment ◽  
Short Circuits ◽  
The Stability ◽  
Wire Arc Additive Manufacturing

In this paper, we present the results of a study on droplet transferring with arc space short circuits during wire-arc additive manufacturing (WAAM GMAW). Experiments were conducted on cladding of single beads with variable welding current and voltage parameters. The obtained oscillograms and video recordings were analyzed in order to compare the time parameters of short circuit and arc burning, the average process peak current, as well as the droplets size. Following the experiments conducted, 2.5D objects were built-up to determine the influence of electrode stickout and welding torch travel speed to identify the droplet transferring and formation features. Moreover, the current–voltage characteristics of the arc were investigated with varying WAAM parameters. Process parameters have been determined that make it possible to increase the stability of the formation of the built-up walls, without the use of specialized equipment for forced droplet transfer. In the course of the research, the following conclusions were established: the most stable drop transfer occurs at an arc length of 1.1–1.2 mm, reverse polarity provides the best drop formation result, the stickout of the electrode wire affects the drop transfer process and the quality of the deposited layers. The dependence of the formation of beads on the number of short circuits per unit length is noted.

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