scholarly journals Experimental Investigation of Additive Manufacturing Using a Hot-Wire Plasma Welding Process on Titanium Parts

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1270
Author(s):  
Pattarawadee Poolperm ◽  
Wasawat Nakkiew ◽  
Nirut Naksuk
Keyword(s):  
Grain Size ◽  
Additive Manufacturing ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Ccd Camera ◽  
Hot Wire ◽  
Plasma Welding ◽  
Welding Wire ◽  
Wire Feeding ◽  
A Charge

In this paper, we propose hot-wire plasma welding, a combination of the plasma welding (PAW) process and the hot-wire process in the additive manufacturing (AM) process. Generally, in plasma welding for AM processes, the deposit grain size increases, and the hardness decreases as the wall height increases. The coarse microstructure, along with the large grain size, corresponds to an increase in deposit temperature, which leads to poorer mechanical properties. At the same time, the hot-wire laser process seems to contain an overly high interstitial amount of oxygen and nitrogen. With an increasing emphasis on sustainability, the hot-wire plasma welding process offers significant advantages: deeper and narrow penetration than the cold-wire plasma welding, improved design flexibility, large deposition rates, and low dilution percentages. Thus, the hot-wire plasma welding process was investigated in this work. The wire used in the welding process was a titanium American Welding Society (AMS) 4951F (Grade 2) welding wire (diameter 1.6 mm), in which the welding was recorded in real time with a charge-coupled device camera (CCD camera). We studied three parameters of the hot-wire plasma welding process: (1) the welding speed, (2) wire current, and (3) wire feeding speed. The mechanical and physical properties (porosity, Vickers hardness, microstructure, and tensile strength) were examined. It was found that the number of layers, the length and width of the molten pool, and the width of the deposited bead increased, while the height of the layer increased, and the hot-wire current played an important role in the deposition. In addition, these results were benchmarked against specimens created by a hot-wire plasma welding/wire-based additive manufacturing process with an intention to develop the hot-wire PAW process as a potential alternative in the additive manufacturing industry.

Plasma Arc Welding for Code Compliance Nuclear Applications

2020 ◽  
Author(s):  
Dongmei (Donna) Sun ◽  
Rob Pistor
Keyword(s):  
Arc Welding ◽  
Welding Process ◽  
Nuclear Industry ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Hot Wire ◽  
Weld Overlay ◽  
Nuclear Component ◽  
Wire Feeding ◽  
Code Compliance

Abstract Plasma Arc Welding (PAW) has been used for many critical applications due to its flexibility, reliability and high weld quality. In this paper, two code compliance plasma arc welding applications in the nuclear industry are discussed. The first application is an innovative welding process using PAW with specially designed dual hot wire feeding system, namely Dual Hot Wire Gas Metal Plasma Arc Welding (GMPAW). The GMPAW process offers unique advantages for high deposition and low dilution weld overlay application. The second application is a remote weld overlay repair from pipe inside diameter (ID) for a highly radiated nuclear component using PAW process with remote machining and NDE capability. In this paper, the benefits and advantages are provided for the aforementioned PAW applications. The versatility of plasma arc welding system configuration, as well as high quality and productivity can make plasma arc welding a good candidate for many critical code compliance applications.

scholarly journals Single-Pass Cladding Process Using Hot-wire Gas Metal Arc Welding Technique

2019 ◽  
Vol 269 ◽  
pp. 01006
Author(s):  
Pattanawit Suntiniwat ◽  
Eakkachai Warinsiriruk ◽  
Sutep Joy-A-Ka
Keyword(s):  
Stainless Steel ◽  
Gas Metal Arc Welding ◽  
Ccd Camera ◽  
Travel Speed ◽  
Hot Wire ◽  
Single Pass ◽  
High Production Rate ◽  
Feeding Speed ◽  
Wire Feeding ◽  
Wire Filler

The aim of this study is to improve cladding process productivity by high production rate with low dilution process by specifying technique as hot-wire GMAW process. The base metal of carbon steel A516 Gr70 was cladded by austenitic stainless steel 309LSi for creating a buttering layer and stainless steel 308LSi for hot-wire filler for topping a cladding layer in a one-pass run. The studied parameters this experiment consist of the feeding ratio of hot wire feeding speed per GMAW wire feeding speed and travel speed. Welding phenomenon during welding was observed by CCD camera with specifying the optical device to see the appropriate condition. The result showed the hot-wire GMAW cladding process could reduce cycle time 3.5 times compare with conventional FCAW cladding process. Moreover, dilution of this process could decrease lower than 15% with acceptable FN 3 on the top of weld surface. Therefore, single pass cladding process achieved by using this method with low dilution by still keep microstructure capability.

scholarly journals Derivation of Appropriate Conditions for Additive Manufacturing Technology Using Hot-Wire Laser Method

2021 ◽  
Vol 3 (1) ◽  
pp. 9
Author(s):  
Song Zhu ◽  
You Nakahara ◽  
Hideki Aono ◽  
Ryo Ejima ◽  
Motomichi Yamamoto
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Technology ◽  
Process Conditions ◽  
In Situ Observation ◽  
Maximum Height ◽  
Hot Wire ◽  
Laser Method ◽  
Additive Manufacturing Technology ◽  
Wire Feeding ◽  
Process Speed

The aim of this research was to develop a high-efficiency and high-material-use additive manufacturing technology using the hot-wire laser method. In this study, the optimization of process conditions using a combination of a high-power diode laser with a relatively large rectangular laser spot and a hot-wire system was investigated. The effects of process parameters such as laser power, process speed, and wire feeding rate (wire feeding speed/process speed) on a bead appearance and cross-sectional characteristics (e.g., effective width, effective height, maximum height, and near net shape rate) were studied in detail. The process phenomena during the multi-layer deposition were investigated by in situ observation via a high-speed camera.

scholarly journals Development of a Resistance Spot Welding Process Using Additive Manufacturing

Metals ◽  
2020 ◽  
Vol 10 (5) ◽  
pp. 555 ◽  
Author(s):  
Márcio Batista ◽  
Valdir Furlanetto ◽  
Sérgio Duarte Brandi
Keyword(s):  
Additive Manufacturing ◽  
Tensile Stress ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Manufacturing Industry ◽  
Low Cost ◽  
Welding Process ◽  
Chemical Compositions ◽  
Automotive Manufacturing ◽  
Resistance Spot

For several decades, the electrical resistance spot welding process has been widely used in the manufacturing of sheet metal structures, especially in automotive bodies. During this period there was no significant development for this welding process. However, in recent years, in order to meet the demand for lighter, economical, and low-cost vehicles, the automotive manufacturing industry is undergoing a revolution in the use of high strength steel sheet combinations, chemical compositions, and of different thicknesses. In this context, the present work focuses on the study and development of a new resistant spot welding technology using additive manufacturing (AMSW) in zinc-coated steel sheets, used in the automotive industry. As a comparison, spot welding was also performed by the conventional resistance spot welding process (RSW). The results showed that the spot welding process using additive manufacturing (AMSW), through the optimized parameters, compared to the conventional resistance spot welding process (RSW), was 34.47% higher in relation to the shear tensile stress, as well as 28.57% higher tensile stress with a perpendicular load to the weld spot. The indentation or thermomechanical mark on the surface of the sheet was imperceptible to the visual inspection, producing a smooth face in the spot region.

scholarly journals Effect of Phase Transformations on Scanning Strategy in WAAM Fabrication

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7871
Author(s):  
Muhammad Hassaan Ali ◽  
You Sung Han
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Phase Transformations ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Stress Generation ◽  
Temperature History ◽  
History Of ◽  
Wire Arc Additive Manufacturing

Due to its high production rates and low cost as compared to other metal additive manufacturing processes, wire arc additive manufacturing (WAAM) has become an emerging technology in the manufacturing industry. However, the residual stress generation and part distortion hinder its widespread adoption because of the complex thermal build-histories of WAAM parts. One of the ways to alleviate this problem is to consider the effects of scan strategies as it directly influences the thermal history of the built part. Since WAAM itself is an evolved welding process and even though it is evident from welding studies that phase transformations directly affect the residual stresses in welded parts, it remains unclear how the consideration of phase transformations for different scan strategies will affect the residual stresses and distortions in the WAAMed parts. A FEM study has been performed to elucidate the effects of phase transformations on residual stresses and the distortion for different deposition patterns. The current findings highlight that for the fabrication of low-carbon martensitic steels: The consideration of phase transformations for line-type discontinuous patterns (alternate and raster) do not significantly affect the residual stresses. Consideration of phase transformations significantly affects residual stresses for continuous patterns (zigzag, in–out and out–in). To accurately simulate complex patterns, phase transformations should be considered because the patterns directly influence the temperature history of the built part and will thus affect the phase transformations, the residual stresses and the warpage. During the fabrication of WAAM parts, whenever possible, discontinuous line scanning patterns should be considered as they provide the part with uniform residual stress and distortion. The alternate line pattern has been found to be the most consistent overall pattern.

scholarly journals In Situ Production of Titanium Aluminides during Wire Arc Additive Manufacturing with Hot-Wire Assisted GMAW Process

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 578 ◽  
Author(s):  
Philipp Henckell ◽  
Yarop Ali ◽  
Andreas Metz ◽  
Jean Pierre Bergmann ◽  
Jan Reimann
Keyword(s):  
Additive Manufacturing ◽  
Titanium Aluminides ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Alloy Formation ◽  
Layer By Layer ◽  
Feeding Rates ◽  
Hot Wire ◽  
Wire Arc Additive Manufacturing

As part of a feasibility study, an alternative production process for titanium aluminides was investigated. This process is based on in situ alloying by means of a multi-wire technique in the layer-wise additive manufacturing process. Thereby, gas metal arc welding (GMAW) was combined with additional hot-wire feeding. By using two separate wires made of titanium and aluminum, it is possible to implement the alloy formation of titanium aluminides directly in the weld bead of the welding process. In this study, wall structures were built layer-by-layer with alloy compositions between 10 at% and 55 at% aluminum by changing the feeding rates. During this investigation, the macroscopic characteristics, microstructural formation, and the change of the microhardness values were analyzed. A close examination of the influence of welding speed and post-process heat treatment on the Ti–47Al alloy was performed; this being particularly relevant due to its economically wide spread applications.

Development of a bio-monitoring system for toxicants in water with fish

2001 ◽  
Vol 1 (2) ◽  
pp. 9-17
Author(s):  
Y.-H. Lee ◽  
H.-K. Lee ◽  
C.-H. Chang ◽  
W.-H. Kim
Keyword(s):  
Monitoring System ◽  
Treatment Plant ◽  
Ccd Camera ◽  
Water Treatment Plant ◽  
Abnormal Behavior ◽  
Time Interval ◽  
Toxic Substances ◽  
Bio Monitoring ◽  
Index Value ◽  
A Charge

A bio-monitoring system for toxicants in water has been developed and verified for actual applications. This system is based on the motionality of five Acheilognathus lanceolata, a fish known to be very sensitive to toxic substances, moving around in an aquarium. Their movements are continuously monitored with a charge coupled device (CCD) camera and analyzed to find and quantify any abnormal behavior in their motional characteristics in comparison with the pre-acquired data. That is, the images of fish captured by a CCD camera are digitalized to identify the location of fish in a constant time interval and the locations of each fish were then analyzed mathematically with a personal computer using the equations proposed to determine the motional characteristics such as floatness, fledness and mobility(agility). These data are then converted by means of fuzzy estimation to an index value, defined as the contamination index (CI), by which the system provides the information about the overall toxic strength of the toxicant in the water flowing into the aquarium. If the fish are exposed to toxicant(s), the CI value will be proportional to the strength of its toxicity. The pilot test was performed in a water treatment plant for six months in order to verify the reproducibility of the system over the unstable conditions such as highly turbid water after rainfall as well as in normal conditions. The test results revealed that this monitoring system has good reproducibility and sensitivity, proving our approach, described in this paper, is reliable. As a result, this approach seems to enable us to make a quick and easy detection of toxic substances contained in water, therefore, this system can be applied to a source of water supply as a toxicant watching system.

scholarly journals Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

2021 ◽  
Vol 11 (10) ◽  
pp. 4694
Author(s):  
Christian Wacker ◽  
Markus Köhler ◽  
Martin David ◽  
Franziska Aschersleben ◽  
Felix Gabriel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
High Energy ◽  
Welding Distortion ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Industrial Use ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

Vibratory weld conditioning during gas tungsten arc welding of al 5052 alloy on the mechanical and micro-structural behavior

2020 ◽  
Vol 17 (6) ◽  
pp. 831-836
Author(s):  
M. Vykunta Rao ◽  
Srinivasa Rao P. ◽  
B. Surendra Babu
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Welded Joints ◽  
Great Influence ◽  
Welding Process ◽  
Microstructural Characterization ◽  
Content Type ◽  
Average Grain Size

Purpose Vibratory weld conditioning parameters have a great influence on the improvement of mechanical properties of weld connections. The purpose of this paper is to understand the influence of vibratory weld conditioning on the mechanical and microstructural characterization of aluminum 5052 alloy weldments. An attempt is made to understand the effect of the vibratory tungsten inert gas (TIG) welding process parameters on the hardness, ultimate tensile strength and microstructure of Al 5052-H32 alloy weldments. Design/methodology/approach Aluminum 5052 H32 specimens are welded at different combinations of vibromotor voltage inputs and time of vibrations. Voltage input is varied from 50 to 230 V at an interval of 10 V. At each voltage input to the vibromotor, there are three levels of time of vibration, i.e. 80, 90 and 100 s. The vibratory TIG-welded specimens are tested for their mechanical and microstructural properties. Findings The results indicate that the mechanical properties of aluminum alloy weld connections improved by increasing voltage input up to 160 V. Also, it has been observed that by increasing vibromotor voltage input beyond 160 V, mechanical properties were reduced significantly. It is also found that vibration time has less influence on the mechanical properties of weld connections. Improvement in hardness and ultimate tensile strength of vibratory welded joints is 16 and 14%, respectively, when compared without vibration, i.e. normal weld conditions. Average grain size is measured as per ASTM E 112–96. Average grain size is in the case of 0, 120, 160 and 230 is 20.709, 17.99, 16.57 and 20.8086 µm, respectively. Originality/value Novel vibratory TIG welded joints are prepared. Mechanical and micro-structural properties are tested.

scholarly journals Spectroscopic flat-fields can be used for precision CCD gain and noise tests

2021 ◽  
Vol 38 ◽  
Author(s):  
J. Gordon Robertson
Keyword(s):  
Ccd Camera ◽  
Matched Pair ◽  
Optical Fibres ◽  
Charge Coupled Device ◽  
Small Areas ◽  
Flat Field ◽  
Basic Parameters ◽  
The Mean ◽  
A Charge ◽  
Analogue To Digital

Abstract One of the basic parameters of a charge coupled device (CCD) camera is its gain, that is, the number of detected electrons per output Analogue to Digital Unit (ADU). This is normally determined by finding the statistical variances from a series of flat-field exposures with nearly constant levels over substantial areas, and making use of the fact that photon (Poisson) noise has variance equal to the mean. However, when a CCD has been installed in a spectroscopic instrument fed by numerous optical fibres, or with an echelle format, it is no longer possible to obtain illumination that is constant over large areas. Instead of making do with selected small areas, it is shown here that the wide variation of signal level in a spectroscopic ‘flat-field’ can be used to obtain accurate values of the CCD gain, needing only a matched pair of exposures (that differ in their realisation of the noise). Once the gain is known, the CCD readout noise (in electrons) is easily found from a pair of bias frames. Spatial stability of the image in the two flat-fields is important, although correction of minor shifts is shown to be possible, at the expense of further analysis.

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