scholarly journals Fabricating Pyramidal Lattice Structures of 304 L Stainless Steel by Wire Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3482 ◽  
Author(s):  
Haorui Zhang ◽  
Junjin Huang ◽  
Changmeng Liu ◽  
Yongsheng Ma ◽  
Yafeng Han ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Lattice Structures ◽  
Layer Height ◽  
Superior Mechanical Properties ◽  
Material Utilization ◽  
Wire Arc Additive Manufacturing ◽  
Dendritic Austenite

Lattice structures have drawn considerable attention due to their superior mechanical properties. However, the existing fabrication methods for lattice structures require complex procedures, as they have low material utilization and lead to unreliable node connections, which greatly restricts their application. In this work, wire arc additive manufacturing is used to fabricate large-scale lattice structures efficiently, without any air holes between rods and panels. The principle and the process of fabricating the rods were analyzed systematically. The influence of the two most important parameters, including heat input and preset layer height, is disclosed. Through optical microscopy, the microstructure of the fabricated steel rods is found to consist of dendritic austenite and skeletal ferrite. The tensile strength of the rods can reach 603 MPa, and their elongation reaches 77%. These experimental results demonstrated the feasibility of fabricating lattice structures using wire arc additive manufacturing.

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.

scholarly journals Wire Arc Additive Manufacturing (WAAM) of Aluminum Alloy AlMg5Mn with Energy-Reduced Gas Metal Arc Welding (GMAW)

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2671 ◽  
Author(s):  
Maximilian Gierth ◽  
Philipp Henckell ◽  
Yarop Ali ◽  
Jonas Scholl ◽  
Jean Pierre Bergmann
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Energy Input ◽  
Large Scale ◽  
Unit Length ◽  
Gas Metal Arc Welding ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Wire Arc Additive Manufacturing

Large-scale aluminum parts are used in aerospace and automotive industries, due to excellent strength, light weight, and the good corrosion resistance of the material. Additive manufacturing processes enable both cost and time savings in the context of component manufacturing. Thereby, wire arc additive manufacturing (WAAM) is particularly suitable for the production of large volume parts due to deposition rates in the range of kilograms per hour. Challenges during the manufacturing process of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with adaptable energy input. In this study, WAAM of AlMg5Mn alloy was systematically investigated by using the gas metal arc welding (GMAW) process. Herein, correlations between the energy input and the resulting temperature–time-regimes show the effect on resulting microstructure, weld seam irregularities and the mechanical properties of additively manufactured aluminum parts. Therefore, multilayer walls were built layer wise using the cold metal transfer (CMT) process including conventional CMT, CMT advanced and CMT pulse advanced arc modes. These processing strategies were analyzed by means of energy input, whereby the geometrical features of the layers could be controlled as well as the porosity to area portion to below 1% in the WAAM parts. Furthermore, the investigations show the that mechanical properties like tensile strength and material hardness can be adapted throughout the energy input per unit length significantly.

scholarly journals Influence of wire arc additive manufacturing of Ti-6Al-4V on microstructure and mechanical properties for potential large-scale aviation parts

2020 ◽  
Vol 321 ◽  
pp. 03037
Author(s):  
D. Elitzer ◽  
H.W. Höppel ◽  
M. Göken ◽  
D. Baier ◽  
C. Fuchs ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
Mechanical Strength ◽  
Large Scale ◽  
Solution Treatment ◽  
Compression Tests ◽  
Process Gas ◽  
Relationship Of ◽  
Wire Arc Additive Manufacturing

As one of the most common Titanium alloys, Ti-6Al-4V faces new challenges concerning the ecological footprint. Due to the current processes, a high metal chip pollution leads to a Buy-to-Fly of 25:1. In this study the parameter / microstructure relationship of Ti-64 on the mechanical properties are discussed. Wire Arc Additive Manufacturing (WAAM) was applied to build samples for microstructural analyses and compression tests. A stress relief (SR) and a solution treatment and annealing (STA) was performed. It was found that SR had no influence on multi-layered samples due to intrinsic heat-treatment. A STA heat-treatment led to a reduction in the mechanical strength. Helium as process gas resulted in an increased mechanical strength due to higher heat capacity compared to argon.

Extending High Value Components Performances with Additive Manufacturing: Application to Naval Applications

2021 ◽  
Vol 319 ◽  
pp. 58-62
Author(s):  
Matthieu Rauch ◽  
Gatien Pechet ◽  
Jean Yves Hascoet ◽  
Guillaume Ruckert
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Electric Arc ◽  
Lattice Structures ◽  
Propeller Blade ◽  
The Many ◽  
Metallic Parts ◽  
The Impact ◽  
Wire Arc Additive Manufacturing

Additive Manufacturing (AM), consists of depositing material in successive layers to obtain the desired part. The parts produced by AM can thus adopt geometries inaccessible by conventional manufacturing means, for example hollow or lattice structures which considerably reduce their weight while keeping or even improving their mechanical properties. Among the many existing processes, Wire Arc Additive Manufacturing (WAAM) is particularly well suited to the manufacture of large metallic parts. It is characterized by a supply of heat in the form of an electric arc (produced by a welding generator) and a supply of material in the form of wire. This paper will discuss the impact of additive manufacturing to enhance the performances of high value components, based on naval application: the manufacturing of a hollow propeller blade demonstrator of 1.5 m high realized in the laboratory.

scholarly journals The Microstructure and Properties of an Al-Mg-0.3Sc Alloy Deposited by Wire Arc Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 320
Author(s):  
Lingling Ren ◽  
Huimin Gu ◽  
Wei Wang ◽  
Shuai Wang ◽  
Chengde Li ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Yield Strength ◽  
Mg Alloy ◽  
Strengthening Effect ◽  
Spherical Diameter ◽  
High Dispersity ◽  
20 Nm ◽  
Wire Arc Additive Manufacturing

Al-Mg alloys can reach medium strength without a solid solution and quenching treatment, thereby avoiding product distortion caused by quenching, which has attracted the attention of wire arc additive manufacturing (WAAM) researchers. However, the mechanical properties of the WAAM Al-Mg alloy deposits obtained so far are poor. Herein, we describe the preparation of Al-Mg-0.3Sc alloy deposits by WAAM and detail the pores, microstructure, and mechanical properties of the alloy produced in this manner. The results showed that the number and sizes of the pores in WAAM Al-Mg-0.3Sc alloy deposits were equivalent to those in Al-Mg alloy deposits without Sc. The rapid cooling characteristics of the WAAM process make the precipitation morphology, size, and distribution of the primary and secondary Al3Sc phases unique and effectively improve the mechanical properties of the deposit. A primary Al3Sc phase less than 3 μm in size was found to precipitate from the WAAM Al-Mg-0.3Sc alloy deposits. The primary Al3Sc phase refines grains, changes the segregated β(Mg2Al3) phase morphology, and ensures that the mechanical properties of horizontal and vertical samples of the deposits are uniform. After heat treatment at 350 °C for 1 h, the WAAM Al-Mg-0.3Sc alloy deposits precipitated a secondary Al3Sc phase, which was spherical (diameter about 20 nm) and had high dispersity. This phase blocks dislocations and subgrain boundaries, causes a noticeable strengthening effect, and further improves the mechanical properties of the deposits, up to a horizontal samples tensile strength of 415 MPa, a yield strength of 279 MPa, and an elongation of 18.5%, a vertical samples tensile strength of 411 MPa, a yield strength of 279 MPa, and an elongation of 14.5%. This Al-Mg-Sc alloy is expected to be widely used in the WAAM field.

scholarly journals Correlations between Microstructure Characteristics and Mechanical Properties in 5183 Aluminium Alloy Fabricated by Wire-Arc Additive Manufacturing with Different Arc Modes

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2075 ◽  
Author(s):  
Xuewei Fang ◽  
Lijuan Zhang ◽  
Guopeng Chen ◽  
Xiaofeng Dang ◽  
Ke Huang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Aluminium Alloy ◽  
Cold Metal Transfer ◽  
Average Pore ◽  
Microstructure Characteristics ◽  
The Difference ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

The effect of arc modes on the microstructure and tensile properties of 5183 aluminium alloy fabricated by cold metal transfer (CMT) processes has been thoroughly investigated. Heat inputs of CMT processes with three arc modes, i.e., CMT, CMT advance (CMT+A), and CMT pulse (CMT+P), were quantified, and their influence on the formation of pores were investigated. The highest tensile strength was found from samples built by the CMT+A process. This agrees well with their smallest average pore sizes. Average tensile strengths of CMT+A arc mode-built samples were 296.9 MPa and 291.8 MPa along the horizontal and vertical directions, respectively. The difference of tensile strength along the horizontal and vertical directions of the CMT+P and CMT samples was mainly caused by the pores at the interfaces between each deposited layer. The successfully built large 5183 aluminium parts by the CMT+A arc mode further proves that this arc mode is a suitable mode for manufacturing of 5183 aluminium alloy.

scholarly journals Mechanical properties of wire arc additive manufactured carbon steel cylindrical component made by gas metal arc welding process

2021 ◽  
Vol 30 (1) ◽  
pp. 188-198
Author(s):  
Bellamkonda Prasanna Nagasai ◽  
Sudersanan Malarvizhi ◽  
Visvalingam Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Large Scale ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Vertical Direction ◽  
Low Carbon ◽  
Cylindrical Component ◽  
Wire Arc Additive Manufacturing

Abstract Wire arc additive manufacturing (WAAM), a welding-based additive manufacturing (AM) method, is a hot topic of research since it allows for the cost-effective fabrication of large-scale metal components at relatively high deposition rates. In the present study, the cylindrical component of low carbon steel (ER70S-6) was built by WAAM technique, using a GMAW torch that was translated by an automated three-axis motion system using a rotation table. The mechanical properties of the component were evaluated by extracting tensile, impact toughness and hardness specimens from the two regions of the building up (vertical) direction. It is found that the tensile properties of the built material exhibited anisotropic characteristics. The yield strength and ultimate tensile strength varied from 333 to 350 MPa and from 429 to 446 MPa, respectively, (less than 5 % variation).

Wire Arc Additive Manufacturing (WAAM): Reviewing Technology, Mechanical Properties, Applications and Challenges

2020 ◽  
Author(s):  
Moosa Zahid ◽  
Khizar Hai ◽  
Mujtaba Khan ◽  
Ahmed Shekha ◽  
Salman Pervaiz ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Manufacturing Sector ◽  
Economic Feasibility ◽  
Inert Gas ◽  
High Deposition Rate ◽  
Design Concepts ◽  
Industrial Sectors ◽  
Wire Arc Additive Manufacturing

Abstract Because of the flexible nature of 3D printing and additive manufacturing technology, manufacturing sector has been revolutionized. There is a possibility to manufacture different intricate geometrics that cannot be produced through conventional processes previously. The conventional design concepts such as design for manufacture (DFM) and design for assembly (DFA) have been modified and simplified. Wire arc additive manufacturing (WAAM) has emerged as one of the leading additive manufacturing (AM) processes due to its high deposition rate and economic feasibility. A lot of progress has been made to understand and improve this process and the mechanical properties associated with the fabricated parts. It is specifically cheaper to print large-scale metallic components using WAAM. This paper gives a thorough review of the work that has been done on WAAM by comparing different technological variants of WAAM, which include Metal Inert Gas (MIG), Tungsten Inert Gas (TIG) and Plasma Arc Welding (PAW). The study also discusses the mechanical properties of the fabricated components using different metals, the defects and challenges the process faces today and how they can be reduced. In the end the study also provides overview of WAAM applications in some of the industrial sectors such as construction, automotive, and structural etc.

scholarly journals High-Temperature Mechanical Properties of IN718 Alloy: Comparison of Additive Manufactured and Wrought Samples

Crystals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 689
Author(s):  
Trunal Bhujangrao ◽  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Edurne Iriondo ◽  
Franck Girot Mata
Keyword(s):  
Mechanical Properties ◽  
High Temperature ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Low Cost ◽  
Tensile Tests ◽  
High Deposition Rate ◽  
High Temperature Mechanical Properties ◽  
Manufacturing Techniques ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) is one of the most appropriate additive manufacturing techniques for producing large-scale metal components with a high deposition rate and low cost. Recently, the manufacture of nickel-based alloy (IN718) using WAAM technology has received increased attention due to its wide application in industry. However, insufficient information is available on the mechanical properties of WAAM IN718 alloy, for example in high-temperature testing. In this paper, the mechanical properties of IN718 specimens manufactured by the WAAM technique have been investigated by tensile tests and hardness measurements. The specific comparison is also made with the wrought IN718 alloy, while the microstructure was assessed by scanning electron microscopy and X-ray diffraction analysis. Fractographic studies were carried out on the specimens to understand the fracture behavior. It was shown that the yield strength and hardness of WAAM IN718 alloy is higher than that of the wrought alloy IN718, while the ultimate tensile strength of the WAAM alloys is difficult to assess at lower temperatures. The microstructure analysis shows the presence of precipitates (laves phase) in WAAM IN718 alloy. Finally, the effect of precipitation on the mechanical properties of the WAAM IN718 alloy was discussed in detail.

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