scholarly journals Effects of Thermal Cycling on Wire and Arc Additive Manufacturing of Al-5356 Components

Metals ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 952
Author(s):  
Markus Köhler ◽  
Jonas Hensel ◽  
Klaus Dilger
Keyword(s):  
Additive Manufacturing ◽  
Thermal Cycling ◽  
Complex Geometry ◽  
Travel Speed ◽  
Process Conditions ◽  
Efficient Production ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Promising Alternative ◽  
Cold Metal

Wire and arc additive manufacturing (WAAM) provides a promising alternative to conventional machining for the production of large structures with complex geometry, as well as individualized low quantity components, using cost-efficient production resources. Due to the layer-by-layer build-up approach, process conditions, such as energy input, deposition patterns and heat conduction during the additive manufacturing process result in a unique thermal history of the structure, affecting the build-up properties. This experimental study aims to describe the effects of thermal cycling on the geometrical and material properties of wire arc additive manufactured Al-5356 aluminum alloy. Under consideration, that Al-5356 is a non-heat treatable alloy, a significant effect on geometrical formation is expected. Linear wall samples were manufactured using pulsed cold metal transfer (CMT-P) under variation of wire-feed rate, travel speed and interpass temperatures. The samples were analyzed in terms of geometry; microstructural composition; hardness and residual stress. Furthermore, the mechanical properties were determined in different building directions.

scholarly journals Wire and Arc Additive Manufacturing of Aluminum Components

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 608 ◽  
Author(s):  
Markus Köhler ◽  
Sierk Fiebig ◽  
Jonas Hensel ◽  
Klaus Dilger
Keyword(s):  
Additive Manufacturing ◽  
Process Development ◽  
Complex Geometry ◽  
Welding Process ◽  
Surface Finishing ◽  
Process Conditions ◽  
Efficient Production ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Wire Arc Additive Manufacturing

An increasing demand for flexibility and product integration, combined with reduced product development cycles, leads to continuous development of new manufacturing technologies such as additive manufacturing. Wire and arc additive manufacturing (WAAM) provides promising technology for the near net-shape production of large structures with complex geometry, using cost efficient production resources such as arc welding technology and wire materials. Compared to powder-based additive manufacturing processes, WAAM offers high deposition rates as well as enhanced material utilization. Because of the layer-by-layer built up approach, process conditions such as energy input, arc characteristics, and material composition result in a different processability during the additive manufacturing process. This experimental study aims to describe the effects of the welding process on buildup accuracy and material properties during wire arc additive manufacturing of aluminum structures. Following a process development using pulse cold metal transfer (CMT-P), linear wall samples were manufactured with variations of the filler metal. The samples were analyzed in terms of surface finishing, hardness, and residual stress. Furthermore, mechanical properties were determined in different building directions.

scholarly journals Analysis of Favorable Process Conditions for the Manufacturing of Thin-Wall Pieces of Mild Steel Obtained by Wire and Arc Additive Manufacturing (WAAM)

Materials ◽  
2018 ◽  
Vol 11 (8) ◽  
pp. 1449 ◽  
Author(s):  
José Prado-Cerqueira ◽  
Ana Camacho ◽  
José Diéguez ◽  
Álvaro Rodríguez-Prieto ◽  
Ana Aragón ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mild Steel ◽  
Steel Wire ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Process Conditions ◽  
Thin Wall ◽  
Cnc Milling ◽  
Cold Metal Transfer ◽  
Cold Metal

One of the challenges in additive manufacturing (AM) of metallic materials is to obtain workpieces free of defects with excellent physical, mechanical, and metallurgical properties. In wire and arc additive manufacturing (WAAM) the influences of process conditions on thermal history, microstructure and resultant mechanical and surface properties of parts must be analyzed. In this work, 3D metallic parts of mild steel wire (American Welding Society-AWS ER70S-6) are built with a WAAM process by depositing layers of material on a substrate of a S235 JR steel sheet of 3 mm thickness under different process conditions, using as welding process the gas metal arc welding (GMAW) with cold metal transfer (CMT) technology, combined with a positioning system such as a computer numerical controlled (CNC) milling machine. Considering the hardness profiles, the estimated ultimate tensile strengths (UTS) derived from the hardness measurements and the microstructure findings, it can be concluded that the most favorable process conditions are the ones provided by CMT, with homogeneous hardness profiles, good mechanical strengths in accordance to conditions defined by standard, and without formation of a decohesionated external layer; CMT Continuous is the optimal option as the mechanical properties are better than single CMT.

Effect of path strategy on residual stress and distortion in laser and cold metal transfer hybrid additive manufacturing

2021 ◽  
pp. 102203
Author(s):  
Runsheng Li ◽  
Guilan Wang ◽  
Xushan Zhao ◽  
Fusheng Dai ◽  
Cheng Huang ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Metal Transfer ◽  
Cold Metal Transfer ◽  
Cold Metal

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.

Additive Manufacturing of Nickel-Based Super Alloys for Aero Engine Applications

2020 ◽  
pp. 48-70
Author(s):  
Raja A. ◽  
Mythreyi O. V. ◽  
Jayaganthan R.
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Source Parameters ◽  
Raw Material ◽  
Layer By Layer ◽  
Powder Bed ◽  
Complex Design ◽  
Direct Energy ◽  
Second Phases ◽  
Metal Addition

Ni based super alloys are widely used in engine turbines because of their proven performance at high temperatures. Manufacturing these parts by additive manufacturing (AM) methods provides researchers a lot of creative space for complex design to improve efficiency. Powder bed fusion (PBF) and direct energy deposition (DED) are the two most widely-used metal AM methods. Both methods are influenced by the source, parameters, design, and raw material. Selective laser melting is one of the laser-based PBF techniques to create small layer thickness and complex geometry with greater accuracy and properties. The layer-by-layer metal addition generates epitaxial growth and solidification in the built direction. There are different second phases in the Ni-based superalloys. This chapter details the micro-segregation of these particles and its influence on the microstructure, and mechanical properties are dependent on the process influencing parameters, the thermal kinetics during the process, and the post-processing treatments.

scholarly journals Analysis and characterization of additive manufacturing processes

2021 ◽  
Vol 13 (4) ◽  
pp. 167-180
Author(s):  
Andra TOFAN-NEGRU ◽  
Cristian BARBU ◽  
Amado STEFAN ◽  
Ioana-Carmen BOGLIS
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Cutting Tools ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Advantages And Disadvantages ◽  
Finishing Processes ◽  
Short Time ◽  
Physical Phenomena ◽  
Am Processes

Recently, additive manufacturing (AM) processes have expanded rapidly in various fields of the industry because they offer design freedom, involve layer-by-layer construction from a computerized 3D model (minimizing material consumption), and allow the manufacture of parts with complex geometry (thus offering the possibility of producing custom parts). Also, they provide the advantage of a short time to make the final parts, do not involve the need for auxiliary resources (cutting tools, lighting fixtures or coolants) and have a low impact on the environment. However, the aspects that make these technologies not yet widely used in industry are poor surface quality of parts, uncertainty about the mechanical properties of products and low productivity. Research on the physical phenomena associated with additive manufacturing processes is necessary for proper control of the phenomena of melting, solidification, vaporization and heat transfer. This paper addresses the relevant additive manufacturing processes and their applications and analyzes the advantages and disadvantages of AM processes compared to conventional production processes. For the aerospace industry, these technologies offer possibilities for manufacturing lighter structures to reduce weight, but improvements in precision must be sought to eliminate the need for finishing processes.

scholarly journals Wire and Arc Additive Manufacturing of High-Strength Al–Zn–Mg Aluminum Alloy

2021 ◽  
Vol 8 ◽  
Author(s):  
Xuewei Fang ◽  
Guopeng Chen ◽  
Jiannan Yang ◽  
Yang Xie ◽  
Ke Huang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Aluminum Alloys ◽  
Electron Backscatter Diffraction ◽  
Vertical Direction ◽  
High Strength ◽  
Thin Wall ◽  
Cold Metal Transfer ◽  
X Ray ◽  
Manufacturing Techniques ◽  
Cold Metal

High-strength 7xxx series aluminum alloys are of great importance for the aerospace industries. However, this type of aluminum alloys has poor processability for most additive manufacturing techniques. In this paper, a newly designed Al–Zn–Mg alloy was used as a feeding wire to fabricate thin wall-shaped samples using the wire and arc additive manufacturing (WAAM) technique. These samples were fabricated based on the cold metal transfer (CMT) process with four different types of arc modes, that is, CMT, CMT-incorporated pulse (CMT + P), CMT-incorporated polarity (CMT + A), CMT-incorporated pulse and polarity (CMT + PA). The optical microscopy, x-ray computed tomography, and scanning electron microscopy equipped with energy-dispersive x-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD) were employed to characterize the microstructure and phase constitution. The results clearly reveal that the porosity varies with the arc modes, and the densest sample with porosity of 0.97% was obtained using the CMT + P mode. The mechanical properties of the fabricated samples are also dependent on the arc modes. The tensile strength and yield strength of the sample manufactured by the CMT + PA arc mode are the highest. In terms of anisotropy, the strength differences in horizontal and vertical direction of the samples made by CMT + PA, CMT + A, and CMT modes are all large, which is mainly ascribed to the pores distributed at the interlayer region.

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