scholarly journals Influence of Deposition Patterns on Distortion of H13 Steel by Wire-Arc Additive Manufacturing

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 485
Author(s):  
Xufeng Li ◽  
Jian Lin ◽  
Zhidong Xia ◽  
Yongqiang Zhang ◽  
Hanguang Fu
Keyword(s):  
Additive Manufacturing ◽  
Temperature History ◽  
H13 Steel ◽  
Deposition Patterns ◽  
Field Distortion ◽  
Set Up ◽  
Manufacturing Technologies ◽  
Inherent Strain ◽  
Inherent Strain Method ◽  
Wire Arc Additive Manufacturing

Wire-arc additive manufacturing (WAAM) has been considered as one of the potential additive-manufacturing technologies to fabricate large components. However, its industrial application is still limited by the existence of stress and distortion. During the process of WAAM, the scanning pattern has an important influence on the temperature field, distortion and final quality of the part. Four kinds of deposition patterns, including sequence, symmetry, in–out and out–in, were designed to deposit H13 steel in this study. An in situ measurement system was set up to record the temperature history and the progress of accumulated distortion of the parts during deposition. An S value was proposed to evaluate the distortion of the substrate. It was shown that the distortion of the part deposited by sequence was significantly larger than those of other parts. The distortion deposited by the out–in pattern decreased by 68.6% compared with sequence. The inherent strain method and strain parameter were introduced to expose the mechanism of distortion reduction caused by pattern variation.

scholarly journals Wire Arc Additive Manufacturing: Review on Recent Findings and Challenges in Industrial Applications and Materials Characterization

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 939
Author(s):  
Mukti Chaturvedi ◽  
Elena Scutelnicu ◽  
Carmen Catalina Rusu ◽  
Luigi Renato Mistodie ◽  
Danut Mihailescu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Structural Integrity ◽  
Industrial Applications ◽  
Raw Material ◽  
Continuous Increase ◽  
Control Optimization ◽  
Modern Manufacturing ◽  
Directed Energy ◽  
Manufacturing Technologies ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a fusion manufacturing process in which the heat energy of an electric arc is employed for melting the electrodes and depositing material layers for wall formation or for simultaneously cladding two materials in order to form a composite structure. This directed energy deposition-arc (DED-arc) method is advantageous and efficient as it produces large parts with structural integrity due to the high deposition rates, reduced wastage of raw material, and low consumption of energy in comparison with the conventional joining processes and other additive manufacturing technologies. These features have resulted in a constant and continuous increase in interest in this modern manufacturing technique which demands further studies to promote new industrial applications. The high demand for WAAM in aerospace, automobile, nuclear, moulds, and dies industries demonstrates compatibility and reflects comprehensiveness. This paper presents a comprehensive review on the evolution, development, and state of the art of WAAM for non-ferrous materials. Key research observations and inferences from the literature reports regarding the WAAM applications, methods employed, process parameter control, optimization and process limitations, as well as mechanical and metallurgical behavior of materials have been analyzed and synthetically discussed in this paper. Information concerning constraints and enhancements of the wire arc additive manufacturing processes to be considered in terms of wider industrial applicability is also presented in the last part of this paper.

scholarly journals Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

2018 ◽  
Vol 190 ◽  
pp. 02005 ◽  
Author(s):  
Markus Hirtler ◽  
Angelika Jedynak ◽  
Benjamin Sydow ◽  
Alexander Sviridov ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Metal Forming ◽  
Batch Size ◽  
Unit Costs ◽  
Batch Sizes ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Forming Tools ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

scholarly journals Wire arc additive manufacturing of mild steel

2018 ◽  
Vol 65 (4) ◽  
pp. 179-186 ◽  
Author(s):  
Damjan Klobčar ◽  
Maja Lindič ◽  
Matija Bušić
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Accuracy ◽  
Welding Parameters ◽  
Welding Robot ◽  
Plasma Welding ◽  
Cold Metal Transfer ◽  
Thin Walls ◽  
Manufacturing Technologies ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

AbstractThis paper presents an overview of additive manufacturing technologies for production of metal parts. A special attention is set to wire arc additive manufacturing (WAAM) technologies, which include MIG/MAG welding, TIG welding and plasma welding. Their advantages compared to laser or electron beam technologies are lower investment and operational costs. However, these processes have lower dimensional accuracy of produced structures. Owing to special features and higher productivity, the WAAM technologies are more suitable for production of bigger parts. WAAM technology has been used together with welding robot and a cold metal transfer (CMT) power source. Thin walls have been produced using G3Si1 welding wire. The microstructure and hardness of produced structures were analysed and measured. A research was done to determine the optimal welding parameters for production of thin walls with smooth surface. A SprutCAM software was used to make a code for 3D printing of sample part.

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.

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