scholarly journals Effects of Material Properties on Angular Distortion in Wire Arc Additive Manufacturing: Experimental and Computational Analyses

Materials ◽  
2020 ◽  
Vol 13 (6) ◽  
pp. 1399
Author(s):  
Sang-Cheol Park ◽  
Hee-Seon Bang ◽  
Woo-Jae Seong
Keyword(s):  
Additive Manufacturing ◽  
Material Properties ◽  
Heat Input ◽  
Coefficient Of Thermal Expansion ◽  
Angular Distortion ◽  
Substrate Thickness ◽  
Deformation Characteristics ◽  
Temperature Dependent ◽  
Temperature Dependent Properties ◽  
Wire Arc Additive Manufacturing

In wire arc additive manufacturing (AM), as in arc welding, arc heat thermally deforms substrates and articles. For industrial applications, deformation characteristics of various materials must be understood and appropriate materials and methods of reducing deformation must be devised. Therefore, angular distortions of different materials were investigated through bead-on-plate welding and finite element analysis. A model that simplifies temperature-dependent properties was developed to establish relationships between thermomechanical properties and angular distortion. A simplified model of temperature-dependent properties was used, and angular distortion characteristics were extensively investigated for different material properties and heat inputs. Coefficient of thermal expansion, density, and specific heat all notably affected angular distortion depending on heat input conditions. Results showed that during wire arc AM, flatness of both substrates and articles could vary depending on material properties, heat input, substrate thickness, and bead accumulation. Study findings can provide insight into deformation characteristics of new materials and how to mitigate thermal distortions.

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 Monotonic and Fatigue Properties of Steel Material Manufactured by Wire Arc Additive Manufacturing

2020 ◽  
Vol 10 (15) ◽  
pp. 5238 ◽  
Author(s):  
Michael Wächter ◽  
Marcel Leicher ◽  
Moritz Hupka ◽  
Chris Leistner ◽  
Lukas Masendorf ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Material Properties ◽  
Elevated Temperatures ◽  
Tensile Tests ◽  
Fatigue Properties ◽  
Practical Applications ◽  
Steel Material ◽  
Characteristic Values ◽  
The One ◽  
Wire Arc Additive Manufacturing

In this study, the monotonic and cyclic material properties of steel material of medium static strength produced additively in the wire arc additive manufacturing (WAAM) process were investigated. This investigated material is expected to be particularly applicable to the field of mechanical engineering, for which practical applications of the WAAM process are still pending and for which hardly any characteristic values can be found in the literature so far. The focus of the investigation was, on the one hand, to determine how the material characteristics are influenced by the load direction in relation to the layered structure and, on the other hand, how they are affected by different interlayer temperatures. For this purpose, monotonic tensile tests were carried out at room temperature as well as at elevated temperatures, and the cyclic material properties were determined. In addition, the hardness of the material and the residual stresses induced during production were measured and compared. In addition to the provision of characteristic properties for the investigated material, it was aimed to determine the extent to which the interlayer temperature influences the strength characteristics, since this can have a considerable influence on the production times and, thus, the economic efficiency of the process.

Thermal Stresses in Materials with Temperature-Dependent Properties

1991 ◽  
Vol 44 (9) ◽  
pp. 383-397 ◽  
Author(s):  
Naotake Noda
Keyword(s):  
Mechanical Properties ◽  
Material Properties ◽  
Metal Forming ◽  
Thermal Stresses ◽  
Main Theme ◽  
Thermal And Mechanical Properties ◽  
Temperature Dependent ◽  
Accurate Analysis ◽  
Thermoelastic Problems ◽  
Temperature Dependent Properties

The present review on thermal stresses in materials with temperature-dependent properties focuses on papers published after 1980. The thermal and mechanical properties in materials subjected to thermal loads due to high temperature, high gradient temperature, and cyclical changes of temperature are dependent on temperature. The main theme of the thermoelastic problems in materials and structures with temperature-dependent material properties is to establish analytical procedures to solve the governing differential equations. In the thermo-inelastic problems, however, we must perform more accurate analysis of the practical problems (weld, heat treatment, metal forming, etc) taking account of the temperature-dependent material properties by use of numerical procedures (finite element methods, mainly).

Vibration analysis of axially moving line supported functionally graded plates with temperature-dependent properties

2013 ◽  
Vol 228 (6) ◽  
pp. 953-969 ◽  
Author(s):  
Hamed Asadi ◽  
Mohammad M Aghdam ◽  
Mahmoud Shakeri
Keyword(s):  
Dynamic Analysis ◽  
Material Properties ◽  
Vibration Analysis ◽  
Volume Fraction ◽  
Functionally Graded ◽  
Laminated Plates ◽  
Functionally Graded Plates ◽  
Temperature Dependent ◽  
Axially Moving ◽  
Temperature Dependent Properties

Vibration analysis of axially moving functionally graded plates with internal line supports and temperature-dependent properties is investigated using harmonic differential quadrature method. The plate is subjected to static in-plane forces while out-of-plane loading is dynamic. Stability of an axially moving plate, traveling at a constant velocity between different supports and experiencing small transverse vibrations are considered. The series of internal rigid line supports parallel to the plate edges are considered together with various arbitrary combinations of boundary conditions. Material properties of the plate are assumed temperature-dependent which is a non-linear function of temperature and differ continuously through thickness according to a power-law distribution of the volume fractions of the plate constituents. Two types of micromechanical models, namely, the Voigt and Mori–Tanaka models are considered. Based on the classical plate theory, the governing equations are obtained for functionally graded plate using the Hamilton’s principle. In the frame of a general dynamic analysis, it is shown that the onset of instability takes place in the form of divergence. The plate may experience divergence or flutter instability at a super critical velocity. Results for dynamic analysis of isotropic and laminated plates are validated with available data in the existing literature, which show excellent agreement. Furthermore, some new results are presented for vibration analysis of functionally graded material plates to study effects of the location of line supports, material properties, volume fraction, temperature, loading, aspect ratio and speed.

scholarly journals Regional Control and Optimization of Heat Input during CMT by Wire Arc Additive Manufacturing: Modeling and Microstructure Effects

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1061
Author(s):  
Furong Chen ◽  
Yihang Yang ◽  
Hualong Feng
Keyword(s):  
Additive Manufacturing ◽  
Deposition Rate ◽  
Thermal History ◽  
Heat Input ◽  
Great Influence ◽  
Input Process ◽  
Cooling Process ◽  
Average Grain Size ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) of aluminum-magnesium (Al–Mg) ER5356 alloy deposits is accomplished by cold metal transfer (CMT). During the process, the temperature change of the alloy deposits has a great influence on molding quality, and the microstructure and properties of alloy deposits are also affected by the complex thermal history of the additive manufacturing process. Here, we used an inter-layer cooling process and controlled the heat input process to attempt to reduce the influence of thermal history on alloy deposits during the additive process. The results showed that inter-layer cooling can optimize the molding quality of alloy deposits, but with the disadvantages of a long test time and slow deposition rate. A simple and uniform reduction of heat input makes the molding quality worse, but controlling the heat input by regions can optimize the molding quality of the alloy deposits. The thermophysical properties of Al-Mg alloy deposits were measured, and we found that the specific heat capacity and thermal diffusivity of alloy deposits were not obviously affected by the temperature. The microstructure and morphology of the deposited specimens were observed and analyzed by microscope and electron back-scatter diffraction (EBSD). The process of controlled heat input results in a higher deposition rate, less side-wall roughness, minimum average grain size, and less coarse recrystallization. In addition, different thermal histories lead to different texture types in the inter-layer cooling process. Finally, a controlled heat input process yields the highest average microhardness of the deposited specimen, and the fluctuation range is small. We expect that the process of controlling heat input by model height region will be widely used in the WAAM field.

scholarly journals A Thermo-Mechanical Analysis of Laser Hot Wire Additive Manufacturing of NAB

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1023
Author(s):  
Glenn W. Hatala ◽  
Qian Wang ◽  
Edward W. Reutzel ◽  
Charles R. Fisher ◽  
Jennifer K. Semple
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Mechanical Analysis ◽  
Simulation Software ◽  
Aluminum Bronze ◽  
Hot Wire ◽  
Temperature Dependent ◽  
Temperature Dependent Properties ◽  
The Impact

There is increased interest in using nickel aluminum bronze (NAB) alloys in large-scale directed energy deposition additive manufacturing (DEDAM) processes for maritime applications, but one challenge lies in the component distortion that results from residual stress generated during fabrication. This paper describes the development and evaluation of thermo-mechanical simulations for laser hot wire (LHW) DEDAM of NAB to predict part distortion. To account for the dearth of temperature-dependent properties for NAB C95800 in open literature and public databases, temperature-dependent material and mechanical properties for NAB C95800 were experimentally measured using test specimens fabricated with a variety of DEDAM processes. Autodesk’s Netfabb Local Simulation software, a commercial finite-element based AM solver, was employed but with its heat source model modified to accommodate LHW DEDAM’s oscillating laser path and additional energy input supplied by the preheated wire feedstock. Thermo-mechanical simulations were conducted using both the acquired temperature-dependent material and mechanical properties and the constant room-temperature properties to assess the impact on simulation accuracy. The usage of constant properties in the thermo-mechanical analysis resulted in significantly different predicted distortion compared to those using the temperature-dependent properties, at times even predicting substrate displacement in an opposite direction.

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.

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