scholarly journals Research Progress of Arc Additive Manufacture Technology

Materials ◽  
2021 ◽  
Vol 14 (6) ◽  
pp. 1415
Author(s):  
Dan Liu ◽  
Boyoung Lee ◽  
Aleksandr Babkin ◽  
Yunlong Chang
Keyword(s):  
Additive Manufacturing ◽  
Research Work ◽  
Manufacturing Technology ◽  
Theoretical Research ◽  
Research Progress ◽  
Additive Manufacture ◽  
High Deposition Rate ◽  
Development History ◽  
Additive Manufacturing Technology ◽  
Wire Arc Additive Manufacturing

Additive manufacturing technology is a special processing technology that has developed rapidly in the past 30 years. The materials used are divided into powder and wire. Additive manufacturing technology using wire as the material has the advantages of high deposition rate, uniform composition, and high density. It has received increasingly more attention, especially for the high efficiency and rapid prototyping of large-size and complex-shaped components. Wire arc additive manufacturing has its unique advantages. The concept, connotation, and development history of arc additive manufacturing technology in foreign countries are reviewed, and the current research status of arc-based metal additive manufacturing technology is reviewed from the principles, development history, process, and practical application of arc additive manufacturing technology. It focuses on the forming system, forming material, residual stress and pores, and other defect controls of the technology, as well as the current methods of mechanical properties and process quality improvement, and the development prospects of arc additive manufacturing technology are prospected. The results show that the related research work of wire arc additive manufacturing technology is still mainly focused on the experimental research stage and has yet not gone deep into the exploration of the forming mechanism. The research work in this field should be more in-depth and systematic from the physical process of forming the molten pool system from the perspectives of stability, the organization evolution law, and performance optimization. We strive to carry out wire arc additive forming technology and theoretical research to promote the application of this technology in modern manufacturing.

Developing Additive Manufacturing Technology for Burner Repair

2016 ◽  
Author(s):  
Olov Andersson ◽  
Andreas Graichen ◽  
Håkan Brodin ◽  
Vladimir Navrotsky
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbines ◽  
Research Work ◽  
Manufacturing Technology ◽  
Heat Radiation ◽  
Original Design ◽  
Repair Work ◽  
Additive Manufacturing Technology ◽  
Low Emission ◽  
Industrial Gas Turbines

Low emission combustion is one of the most important requirements for Industrial gas turbines. Siemens Industrial gas turbines SGT-800 and SGT-700 use DLE (Dry Low Emission) technology and are equipped with 3rd generation of DLE burners. These burners demonstrate high performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially the tip repair has been done by conventional methods — i.e. cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of AM (Additive Manufacturing) technology it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including: a) machining off of the damaged and oxidized tip, b) positioning the sintered model on the burner face, c) sintering a new tip in place, d) quality assurance and inspection methods, e) powder handling, f) material qualification including bonding zone, g) development of methods for mechanical integrity calculation, h) qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification and repair work shop set-up.

scholarly journals Characterization of Microstructure and Mechanical Properties of Stellite 6 Part Fabricated by Wire Arc Additive Manufacturing

Metals ◽  
2019 ◽  
Vol 9 (4) ◽  
pp. 474 ◽  
Author(s):  
Zixiang Li ◽  
Yinan Cui ◽  
Jie Wang ◽  
Changmeng Liu ◽  
Jiachen Wang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Stress Relief ◽  
Manufacturing Technology ◽  
Additive Manufacturing Technology ◽  
Stellite 6 ◽  
Average Hardness ◽  
Traditional Processing ◽  
Wire Arc Additive Manufacturing

Stellite 6 alloy has excellent wear resistance, corrosion resistance, and oxidation resistance, however the difficulties in traditional processing limit its wide application. Additive manufacturing technology that has emerged in recent years is expected to provide a new way for the processing of stellite 6 alloy. In this study, two square thin-walled stellite 6 parts were fabricated through the wire arc additive manufacturing technology. At the same time, the effect of stress relief annealing on the mechanical performance of the fabricated stellite 6 part was studied and compared with the corresponding casting part. The results indicate that the additive manufacturing stellite 6 components exhibit satisfactory quality and appearance. Moreover, the microstructure of the additive manufacturing part is much finer than that of the casting part. From the substrate to the top region of the additive manufacturing part, the morphology of the dendrites changes from columnar to equiaxed, and the hardness increases firstly and then decreases gradually. In addition, the average hardness of the additive manufacturing part is ~7–8 HRC higher than the casting part. The ultimate tensile strength and yield strength is ~150MPa higher than the casting part, while the elongation is almost the same. The stress relief annealing has no significant effect on the hardness of the AM part, but it can slightly improve the strength.

Developing Additive Manufacturing Technology for Burner Repair

2016 ◽  
Vol 139 (3) ◽  
Author(s):  
Olov Andersson ◽  
Andreas Graichen ◽  
Håkan Brodin ◽  
Vladimir Navrotsky
Keyword(s):  
Additive Manufacturing ◽  
Gas Turbines ◽  
Research Work ◽  
Manufacturing Technology ◽  
Heat Radiation ◽  
Original Design ◽  
Repair Work ◽  
Additive Manufacturing Technology ◽  
Low Emission ◽  
Industrial Gas Turbines

Low emission combustion is one of the most important requirements for industrial gas turbines. Siemens industrial gas turbines SGT-800 and SGT-700 use dry low emission (DLE) technology and are equipped with third generation of DLE burners. These burners demonstrate high-performance and reliable operation for the duration of their design lifetime. The design and shape of the burner tip is of great importance in order to achieve a good fuel/ air mixture and at the same time a resistance to the fatigue created by heat radiation input. This gives a requirement for a tip structure with delicate internal channels combined with thicker structure for load carrying and production reasons. It was found that the extension of the burner lifetime beyond the original design life could be accomplished by means of repair of the burner tip. Initially, the tip repair has been done by conventional methods— i.e., cutting off the tip and replacing it with a premanufactured one. Due to the sophisticated internal structure of the burner, the cuts have to be made fairly high upstream to avoid having the weld in the delicate channel area. Through the use of additive manufacturing (AM) technology, it has been possible to simplify the repair and only replace the damaged part of the tip. Special processes have been developed for AM repair procedure, including the following: machining off of the damaged and oxidized tip, positioning the sintered model on the burner face, sintering a new tip in place, quality assurance and inspection methods, powder handling, material qualification including bonding zone, development of methods for mechanical integrity calculation, and qualification of the whole repair process. This paper describes how we have developed and qualified SGT-800 and SGT-700 DLE burners repair with the help of additive manufacturing technology and our research work performed. In addition, this paper highlights the challenges we faced during design, materials qualification, and repair work shop set up.

scholarly journals Experimental Investigation on Bead Geometry Parameter and Mechanical Property of Part Fabricated by Wire Arc Additive Manufacturing

2021 ◽  
Author(s):  
Soundrapanidan Eswaran ◽  
◽  
Vivekkumar Panneerselvam ◽  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Manufacturing Industry ◽  
Research Work ◽  
Process Time ◽  
Material Strength ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Printed Materials ◽  
Wire Arc Additive Manufacturing

In additive manufacturing process, wire arc additive manufacturing process (WAAM) is a technique which can produce a metal 3D printed part. In Industries product are produced by wasting one third of its material, from this process time consumption and material wastage is more comparing in Subtractive Manufacturing over Additive Manufacturing. Additive Manufacturing stepped from 1925 in manufacturing industry and it has gained its remarkable growth in past few decades, as of now metal 3D oriented parts have come to play a major role in aerospace industry. This research work focused on Gas Metal Arc Welding (GMAW) welding. It has high deposition rate, ultimate build volume and good structural integrity compare with other additive manufacturing process. MACH3 controller is used to control the welding torch motion for addition of material by 3 axis movement (X, Y and Z). To identify the correct parameters for metal part we have done numbers of samples by changing values in the MIG machine from that we finalize the three parameters through visualizes on the printed materials after that a wall like structure is built and post processing like cutting the materials from base plate, grinding the uneven surface on printed materials. The printed materials are ready for material testing like bead geometry analysis of various parameter and tensile testing to identify the printed material strength, elongation, stress and strain.

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.

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