Effect of Filler Metal Type on Microstructure and Mechanical Properties of Fabricated NiAl Bronze Alloy Using Wire Arc Additive Manufacturing System

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.

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Correlations between Microstructure Characteristics and Mechanical Properties in 5183 Aluminium Alloy Fabricated by Wire-Arc Additive Manufacturing with Different Arc Modes

Materials ◽

10.3390/ma11112075 ◽

2018 ◽

Vol 11 (11) ◽

pp. 2075 ◽

Cited By ~ 12

Author(s):

Xuewei Fang ◽

Lijuan Zhang ◽

Guopeng Chen ◽

Xiaofeng Dang ◽

Ke Huang ◽

...

Keyword(s):

Mechanical Properties ◽

Tensile Strength ◽

Additive Manufacturing ◽

Aluminium Alloy ◽

Cold Metal Transfer ◽

Average Pore ◽

Microstructure Characteristics ◽

The Difference ◽

Cold Metal ◽

Wire Arc Additive Manufacturing

The effect of arc modes on the microstructure and tensile properties of 5183 aluminium alloy fabricated by cold metal transfer (CMT) processes has been thoroughly investigated. Heat inputs of CMT processes with three arc modes, i.e., CMT, CMT advance (CMT+A), and CMT pulse (CMT+P), were quantified, and their influence on the formation of pores were investigated. The highest tensile strength was found from samples built by the CMT+A process. This agrees well with their smallest average pore sizes. Average tensile strengths of CMT+A arc mode-built samples were 296.9 MPa and 291.8 MPa along the horizontal and vertical directions, respectively. The difference of tensile strength along the horizontal and vertical directions of the CMT+P and CMT samples was mainly caused by the pores at the interfaces between each deposited layer. The successfully built large 5183 aluminium parts by the CMT+A arc mode further proves that this arc mode is a suitable mode for manufacturing of 5183 aluminium alloy.

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Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Metals ◽

10.3390/met8121009 ◽

2018 ◽

Vol 8 (12) ◽

pp. 1009 ◽

Cited By ~ 10

Author(s):

Marcel Graf ◽

Andre Hälsig ◽

Kevin Höfer ◽

Birgit Awiszus ◽

Peter Mayr

Keyword(s):

Mechanical Properties ◽

Finite Element ◽

Additive Manufacturing ◽

Gas Metal Arc Welding ◽

Welding Process ◽

Temperature Fields ◽

Filler Materials ◽

Cold Metal Transfer ◽

Cold Metal ◽

Wire Arc Additive Manufacturing

Additive manufacturing processes have been investigated for some years, and are commonly used industrially in the field of plastics for small- and medium-sized series. The use of metallic deposition material has been intensively studied on the laboratory scale, but the numerical prediction is not yet state of the art. This paper examines numerical approaches for predicting temperature fields, distortions, and mechanical properties using the Finite Element (FE) software MSC Marc. For process mapping, the filler materials G4Si1 (1.5130) for steel, and AZ31 for magnesium, were first characterized in terms of thermo-physical and thermo-mechanical properties with process-relevant cast microstructure. These material parameters are necessary for a detailed thermo-mechanical coupled Finite Element Method (FEM). The focus of the investigations was on the numerical analysis of the influence of the wire feed (2.5–5.0 m/min) and the weld path orientation (unidirectional or continuous) on the temperature evolution for multi-layered walls of miscellaneous materials. For the calibration of the numerical model, the real welding experiments were carried out using the gas-metal arc-welding process—cold metal transfer (CMT) technology. A uniform wall geometry can be produced with a continuous welding path, because a more homogeneous temperature distribution results.

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Wire Arc Additive Manufacturing (WAAM) of Aluminum Alloy AlMg5Mn with Energy-Reduced Gas Metal Arc Welding (GMAW)

Materials ◽

10.3390/ma13122671 ◽

2020 ◽

Vol 13 (12) ◽

pp. 2671 ◽

Cited By ~ 1

Author(s):

Maximilian Gierth ◽

Philipp Henckell ◽

Yarop Ali ◽

Jonas Scholl ◽

Jean Pierre Bergmann

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Arc Welding ◽

Energy Input ◽

Large Scale ◽

Unit Length ◽

Gas Metal Arc Welding ◽

Cold Metal Transfer ◽

Metal Arc Welding ◽

Wire Arc Additive Manufacturing

Large-scale aluminum parts are used in aerospace and automotive industries, due to excellent strength, light weight, and the good corrosion resistance of the material. Additive manufacturing processes enable both cost and time savings in the context of component manufacturing. Thereby, wire arc additive manufacturing (WAAM) is particularly suitable for the production of large volume parts due to deposition rates in the range of kilograms per hour. Challenges during the manufacturing process of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with adaptable energy input. In this study, WAAM of AlMg5Mn alloy was systematically investigated by using the gas metal arc welding (GMAW) process. Herein, correlations between the energy input and the resulting temperature–time-regimes show the effect on resulting microstructure, weld seam irregularities and the mechanical properties of additively manufactured aluminum parts. Therefore, multilayer walls were built layer wise using the cold metal transfer (CMT) process including conventional CMT, CMT advanced and CMT pulse advanced arc modes. These processing strategies were analyzed by means of energy input, whereby the geometrical features of the layers could be controlled as well as the porosity to area portion to below 1% in the WAAM parts. Furthermore, the investigations show the that mechanical properties like tensile strength and material hardness can be adapted throughout the energy input per unit length significantly.

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On the Effect of Heat Input and Interpass Temperature on the Performance of Inconel 625 Alloy Deposited Using Wire Arc Additive Manufacturing–Cold Metal Transfer Process

Metals ◽

10.3390/met12010046 ◽

2021 ◽

Vol 12 (1) ◽

pp. 46

Author(s):

Chengxun Zhang ◽

Zhijun Qiu ◽

Hanliang Zhu ◽

Zhiyang Wang ◽

Ondrej Muránsky ◽

...

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Heat Input ◽

Inconel 625 ◽

Heat Accumulation ◽

Cold Metal Transfer ◽

Inconel 625 Alloy ◽

Cold Metal ◽

Wire Arc Additive Manufacturing ◽

Interpass Temperature

Relatively high heat input and heat accumulation are treated as critical challenges to affect the qualities and performances of components fabricated by wire arc additive manufacturing (WAAM). In this study, various heat inputs, namely 276, 552 and 828 J/mm, were performed to fabricate three thin-wall Inconel 625 structures by cold metal transfer (CMT)-based WAAM, respectively, and active interpass cooling was conducted to limit heat accumulation. The macrostructure, microstructure and mechanical properties of the produced components by CMT were investigated. It was found that the increased heat input can deteriorate surface roughness, and the size of dendrite arm spacing increases with increasing heat input, thus leading to the deterioration of mechanical properties. Lower heat input and application of active interpass cooling can be an effective method to refine microstructure and reduce anisotropy. This study enhances the understanding of interpass temperature control and the effectiveness of heat inputs for Inconel 625 alloy by WAAM. It also provides a valuable in situ process for microstructure and mechanical properties’ refinement of WAAM-fabricated alloys and the control of heat accumulation for the fabrication of large-sized structures for future practical applications.

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Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406221998402 ◽

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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Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

Materials ◽

10.3390/ma13071610 ◽

2020 ◽

Vol 13 (7) ◽

pp. 1610 ◽

Cited By ~ 3

Author(s):

Paulo J. Morais ◽

Bianca Gomes ◽

Pedro Santos ◽

Manuel Gomes ◽

Rudolf Gradinger ◽

...

Keyword(s):

Mechanical Properties ◽

Heat Treatment ◽

Additive Manufacturing ◽

High Performance ◽

Mechanical Performance ◽

Fluorescence Analysis ◽

Cold Metal Transfer ◽

Direction Parallel ◽

X Ray ◽

Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

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Effect of pulsed metal inert gas (pulsed-MIG) and cold metal transfer (CMT) techniques on hydrogen dissolution in wire arc additive manufacturing (WAAM) of aluminium

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-020-04946-2 ◽

2020 ◽

Vol 107 (1-2) ◽

pp. 311-331 ◽

Cited By ~ 1

Author(s):

Karan S. Derekar ◽

Adrian Addison ◽

Sameehan S. Joshi ◽

Xiang Zhang ◽

Jonathan Lawrence ◽

...

Keyword(s):

Additive Manufacturing ◽

Metal Transfer ◽

Inert Gas ◽

Cold Metal Transfer ◽

Cold Metal ◽

Wire Arc Additive Manufacturing ◽

Hydrogen Dissolution

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Microstructure and Mechanical Properties of AlSi7Mg0.6 Aluminum Alloy Fabricated by Wire and Arc Additive Manufacturing Based on Cold Metal Transfer (WAAM-CMT)

Materials ◽

10.3390/ma12162525 ◽

2019 ◽

Vol 12 (16) ◽

pp. 2525 ◽

Cited By ~ 4

Author(s):

Qingfeng Yang ◽

Cunjuan Xia ◽

Yaqi Deng ◽

Xianfeng Li ◽

Haowei Wang

Keyword(s):

Mechanical Properties ◽

Heat Treatment ◽

Additive Manufacturing ◽

Shape Change ◽

Rapid Development ◽

Engineering Application ◽

Metal Transfer ◽

Cold Metal Transfer ◽

Microstructure And Mechanical Properties ◽

Cold Metal

Wire and arc additive manufacturing based on cold metal transfer (WAAM-CMT) has aroused wide public concern in recent years as one of the most advanced technologies for manufacturing components with complex geometries. However, the microstructure and mechanical properties of the parts fabricated by WAAM-CMT technology mostly are intolerable for engineering application and should be improved necessarily. In this study, heat treatment was proposed to optimize the microstructure and enhance mechanical properties in the case of AlSi7Mg0.6 alloy. After heat treatment, the division between coarse grain zone and fine grain zone of as-deposited samples seemed to disappear and the distribution of Si and Mg elements was more uniform. What is more, the yield strength and ultimate tensile strength were improved significantly, while the ductility could be sustained after heat treatment. The improvement of strength is attributed to precipitation strengthening, and the shape change of Si phase. No reduction in ductility is due to the higher work hardening rate caused by nanostructured precipitate. It is proved that heat treatment as an effective method can control the microstructure and enhance comprehensive mechanical properties, which will boost rapid development of WAAM industrial technology.

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