scholarly journals Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4265
Author(s):  
Bobo Li ◽  
Bowen Wang ◽  
Greg Zhu ◽  
Lijuan Zhang ◽  
Bingheng Lu
Keyword(s):  
Additive Manufacturing ◽  
High Surface ◽  
Deposition Process ◽  
High Energy ◽  
Width Ratio ◽  
Thin Wall ◽  
Small Power ◽  
High Surface Quality ◽  
Wall Structures ◽  
Wire Feed

Aiming at handling the contradiction between power constraint of on-orbit manufacturing and the high energy input requirement of metal additive manufacturing (AM), this paper presents an AM process based on small-power metal fine wire feed, which produces thin-wall structures of height-to-width ratio up to 40 with core-forming power only about 50 W. In this process, thermal resistance was introduced to optimize the gradient parameters which greatly reduces the step effect of the typical AM process, succeeded in the surface roughness (Ra) less than 5 μm, comparable with that obtained by selective laser melting (SLM). After a 10 min electrolyte-plasma process, the roughness of the fabricated specimen was further reduced to 0.4 μm, without defects such as pores and cracks observed. The ultimate tensile strength of the specimens measured about 500 MPa, the relative density was 99.37, and the Vickers hardness was homogeneous. The results show that the proposed laser-Joule wire feed-direct metal deposition process (LJWF-DMD) is a very attractive solution for metal AM of high surface quality parts, particularly suitable for rapid prototyping for on-orbit AM in space.

scholarly journals Self-adaptive control system for additive manufacturing using double electrode micro plasma arc welding

2020 ◽  
Author(s):  
Nan Li ◽  
Ding Fan ◽  
Jiankang Huang ◽  
Shurong Yu ◽  
Wen Yuan ◽  
...  
Keyword(s):  
Control System ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Deposition Process ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Metal Parts ◽  
Double Electrode ◽  
Micro Plasma Arc Welding ◽  
Wire Feed

Abstract Wire arc additive manufacturing (WAAM) has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost. However, in the process of automatically manufacturing the high-quality metal parts by WAAM, several problems about the heat build-up, the deposit-path optimization, and the stability of the process parameters need to be well addressed. To overcome these issues, a new WAAM method based on the double electrode micro plasma arc welding (DE-MPAW) was designed. The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically. The effects between the parameters, wire feed rate and torch stand-off distance, in the process of WAAM were investigated experimentally. In addition, a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance . Finally, a series of tests were performed to evaluate the control system’s performance . The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system. Further, the deposition paths about the metal part’s layer heights in WAAM are simplified. Finally, the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

scholarly journals Investigation of Microstructure and Mechanical Performance of IN738LC Superalloy Thin Wall Produced by Pulsed Plasma Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 3924
Author(s):  
Kaibo Wang ◽  
Zhe Sun ◽  
Yuxin Liu ◽  
Yaohui Lv
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Eutectic Reaction ◽  
Bimodal Distribution ◽  
High Energy ◽  
Thin Wall ◽  
Pulsed Plasma ◽  
Plasma Arc ◽  
Heat Accumulation ◽  
Energy Beam

The IN738LC Ni-based superalloy strengthened by the coherent γ′-Ni3(Al,Ti) intermetallic compound is one of the most employed blade materials in gas turbine engines and IN738LC thin wall components without macro-cracks were fabricated by pulsed plasma arc additive manufacturing (PPAAM), which is more competitive when considering convenience and cost in comparison with other high-energy beam additive manufacturing technologies. The as-fabricated sample exhibited epitaxial growth columnar dendrites along the building direction with discrepant secondary arm spacing due to heat accumulation. A lot of fine γ′ particles with an average size of 81 nm and MC carbides were observed in the interdendritic region. Elemental segregation and γ–γ′ eutectic reaction were analyzed in detail and some MC carbides were confirmed in the reaction L + MC→γ + γ′. After standard heat treatment, bimodal distribution of γ′ phases, including coarse γ′ particles (385 nm, 42 vol.%) and fine γ′ particles (42 nm, 25 vol.%), was observed. The mechanism of microstructural evolution, phase formation, as well as cracking mechanisms were discussed. Microhardness and tensile tests were carried out to investigate the mechanical performance. The results show that both the as-fabricated and heat-treated samples exhibited a higher tensile strength but a slightly lower ductility compared with cast parts.

scholarly journals Self-Adaptive Control System for Additive Manufacturing Using Double Electrode Micro Plasma Arc Welding

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Nan Li ◽  
Ding Fan ◽  
Jiankang Huang ◽  
Shurong Yu ◽  
Wen Yuan ◽  
...  
Keyword(s):  
Control System ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Deposition Process ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Metal Parts ◽  
Double Electrode ◽  
Micro Plasma Arc Welding ◽  
Wire Feed

AbstractWire arc additive manufacturing (WAAM) has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost. However, in the process of automatically manufacturing the high-quality metal parts by WAAM, several problems about the heat build-up, the deposit-path optimization, and the stability of the process parameters need to be well addressed. To overcome these issues, a new WAAM method based on the double electrode micro plasma arc welding (DE-MPAW) was designed. The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically. The effects between the parameters, wire feed rate and torch stand-off distance, in the process of WAAM were investigated experimentally. In addition, a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance. Finally, a series of tests were performed to evaluate the control system’s performance. The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system. Further, the deposition paths about the metal part’s layer heights in WAAM are simplified. Finally, the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

scholarly journals Measurement and Modeling of Forces in Extrusion-Based Additive Manufacturing of Flexible Silicone Elastomer With Thin Wall Structures

2018 ◽  
Vol 140 (9) ◽  
Author(s):  
Jeffrey Plott ◽  
Xiaoqing Tian ◽  
Albert Shih
Keyword(s):  
Additive Manufacturing ◽  
Bending Moment ◽  
Volumetric Flow Rate ◽  
Prosthetic Hand ◽  
Thin Wall ◽  
Layer Height ◽  
Normal Forces ◽  
Wall Structures ◽  
Resistance Approach ◽  
Inner Diameter

Flexible thin wall silicone parts fabricated via extrusion-based additive manufacturing (AM) tend to deform due to the AM forces, limiting the maximum build height. The tangential and normal forces in AM were measured to investigate effects of three key process parameters (volumetric flow rate Q, nozzle tip inner diameter di, and layer height t) on the build height. The interaction between the nozzle tip and the extruded silicone bead is controlled to prevent interaction, flatten the top surface of the extruded silicone, or immerse the nozzle in the extruded silicone. Results show that tangential and normal forces in AM strongly depend on this interaction. Specifically, the AM forces remained low (less than 0.2 mN) if the nozzle tip did not contact the extruded silicone bead. Once the nozzle interaction with extruded silicone came into effect, the AM forces quickly grew to over 1 mN. The single wall tower configuration was developed to determine a predictive deflection resistance approach based on the measured AM forces and the resultant bending moment of inertia. This approach shows that a smaller di can produce taller towers, while a larger di is better at bridging and overhangs. These results are applied to the AM of a hollow thin wall silicone prosthetic hand.

scholarly journals Study of the Mechanism of a Stable Deposited Height During GMAW-Based Additive Manufacturing

2020 ◽  
Vol 10 (12) ◽  
pp. 4322
Author(s):  
Hongyao Shen ◽  
Rongxin Deng ◽  
Bing Liu ◽  
Sheng Tang ◽  
Shun Li
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Gas Metal Arc Welding ◽  
Research Work ◽  
Dimensional Accuracy ◽  
Deposition Process ◽  
High Deposition Rate ◽  
Thin Wall ◽  
Forming Process ◽  
Layer Height

Gas metal arc welding (GMAW)-based additive manufacturing has the advantages of a high deposition rate, low cost, the production of a compact and dense microstructure in the cladding layer, and good mechanical properties, but the forming process is unstable. The shape of the welding bead critically affects the layer height and dimensional accuracy of the parts manufactured, and it is difficult to control. A series of experiments were designed and the results indicated that when the value of the predefined layer height is set in a certain range and other parameters are held constant, the height of the thin wall produced by GMAW-based additive manufacturing is almost equal to the predefined layer height multiplied by the number of layers. This research work shows that during the GMAW process, the changes in the distance between the torch and the top surface of the part cause a variety of dry extensions of the electrode; furthermore, the changes lead to a variety in the heat input into the molten pool. Therefore, the dry extension of the electrode is the key factor influencing the geometry of the welding bead, especially the layer height, and it has a compensating effect that makes the actual layer height close to the predefined value. A three-dimensional numerical model was established to study the influence of the predefined layer height to the fluid flow and heat transfer behaviors during the weld-deposition process.

scholarly journals Innovation in additive manufacturing of parts from aluminium matrix composites

2018 ◽  
Vol 224 ◽  
pp. 01073 ◽  
Author(s):  
Tatiana Tarasova ◽  
Galina Gvozdeva ◽  
Riana Ableyeva
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Formation Process ◽  
Thin Wall ◽  
Matrix Composites ◽  
Modern Equipment ◽  
Minimal Width ◽  
Thin Walls ◽  
Wall Structures

The laser build-up cladding is a well-known technique for additive manufacturing tasks. Modern equipment for the laser cladding enables material to be deposited with the lateral resolution of about 100 μm and to manufacture miniature parts. In this paper the laser micro cladding process was investigated to produce miniature thin-wall parts of Al-based composites. Thin walls formation process by subsequent single tracks overlapping with vertical increment was investigated. The influence of the cladding parameters on the minimal width and the quality of the fabricated thin walls was examined. The thin walls with the minimal width of 140 μm and surface roughness Ra 1,5 μm were generated. Laser micro cladding potential to manufacture lattice-shaped structures of Al-Si composites was shown. Fabricated thin-wall structures can have application in different fields e.g. aviation, automotive and tooling industries.

scholarly journals A Multiaxis Tool Path Generation Approach for Thin Wall Structures Made with WAAM

2021 ◽  
Vol 5 (4) ◽  
pp. 128
Author(s):  
Matthieu Rauch ◽  
Jean-Yves Hascoet ◽  
Vincent Querard
Keyword(s):  
Additive Manufacturing ◽  
High Performance ◽  
Tool Path ◽  
Tool Path Generation ◽  
Path Generation ◽  
Thin Wall ◽  
Process Data ◽  
Technical Data ◽  
Wall Structures ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) has emerged over the last decade and is dedicated to the realization of high-dimensional parts in various metallic materials. The usual process implementation consists in associating a high-performance welding generator as heat source, a NC controlled 6 or 8 degrees (for example) of freedom robotic arm as motion system and welding wire as feedstock. WAAM toolpath generation methods, although process specific, can be based on similar approaches developed for other processes, such as machining, to integrate the process data into a consistent technical data environment. This paper proposes a generic multiaxis tool path generation approach for thin wall structures made with WAAM. At first, the current technological and scientific challenges associated to CAD/CAM/CNC data chains for WAAM applications are introduced. The focus is on process planning aspects such as non-planar non-parallel slicing approaches and part orientation into the working space, and these are integrated in the proposed method. The interest of variable torch orientation control for complex shapes is proposed, and then, a new intersection crossing tool path method based on Design For Additive Manufacturing considerations is detailed. Eventually, two industrial use cases are introduced to highlight the interest of this approach for realizing large components.

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