An Analytical Model for Filler Wire Heating and Melting during Wire Feed Laser Deposition

2019 ◽  
Vol 822 ◽  
pp. 431-437 ◽  
Author(s):  
D.V. Mukin ◽  
Sergei Yu. Ivanov ◽  
Ekaterina A. Valdaitseva ◽  
Gleb A. Turichin ◽  
Alexander E. Beniash
Keyword(s):  
Analytical Model ◽  
Feed Rate ◽  
Analytical Methods ◽  
Laser Deposition ◽  
Computational Time ◽  
Filler Wire ◽  
Functional Analytical Methods ◽  
Melting Surface ◽  
The Wire ◽  
Wire Feed

Additive technologies, in particular, wire-feed laser deposition, can significantly reduce the production cycle of manufacturing large-sized parts or parts of complex shape due to partial or complete elimination of technological operations such as casting, machining and welding. The aim of the work is to develop an analytical model of heating and melting of the filler wire during wire-feed laser deposition. The heat conduction problem was solved by the functional-analytical methods. The practical effectiveness of the functional-analytical methods with respect to computational time is several orders of magnitude higher than numerical ones. Obtained analytical solution made it possible to determine the temperature field for heat flux arbitrarily distributed on the filler wire surface. It is established that at a higher feed rate, the wire tip is completely melted at a greater distance from the laser axis. The shape of the melting surface also depends on the feed rate. At a slow feed rate, a more uniform heating of the wire over the cross section occurs. The melting surface has a small angle of inclination.

Multi-Objective Optimisation of Laser Deposition of Metal Matrix Composites for Surface Coating Using Principal Component Analysis

2018 ◽  
Vol 40 ◽  
pp. 9-21 ◽  
Author(s):  
Peter Kayode Farayibi
Keyword(s):  
Feed Rate ◽  
Surface Coating ◽  
Laser Power ◽  
Traverse Speed ◽  
Laser Deposition ◽  
Powder Feed Rate ◽  
Multi Objective ◽  
Powder Feed ◽  
Output Characteristics ◽  
Wire Feed

Laser deposition is an advanced manufacturing technology capable of enhancing service life of engineering components by hard-facing their functional surfaces. There are quite a number of parameters involved in the process and also desirable output characteristics. These output characteristics are often independently optimised and which may lead to poor outcome for other characteristics, hence the need for multi-objective optimisation of all the output characteristics. In this study, a laser deposition of Ti-6Al-4V wire and tungsten carbide powder was made on a Ti-6Al-4V substrate with a view to achieve a metallurgical bonded metal matrix composite on the substrate. Single clads were deposited with a desire to optimise the composite clad characteristics (height, width and reinforcement fraction) for the purpose of surface coating. Processing parameters (laser power, traverse speed, wire feed rate, powder feed rate) were varied, the experiment was planned using Taguchi method and output characteristics were analysed using principal component analysis approach. The results indicated that the parameters required for optimised clad height, width, and reinforcement fraction necessary for surface coating is laser power of 1800 W, traverse speed of 200 mm/min, wire feed rate 700 mm/min and powder feed rate of 30 g/min. The powder feed rate was found to most significantly contribute 43.99%, followed by traverse speed 39.77%, laser power 15.87% with wire feed rate having the least contribution towards the multi-objective optimisation. Confirmation results showed that clad width and reinforcement fraction were significantly improved by the optimised parameters. The multi-objective optimisation procedure is a useful tool necessary to identify the process factors required to enhance output characteristics in laser processing.

Fiber Laser Deposition of Nickel-Based Superalloys Using Filler Wire Feed

2015 ◽  
Author(s):  
Y. N. Zhang ◽  
X. Cao ◽  
P. Wanjara
Keyword(s):  
Fiber Laser ◽  
Continuous Wave ◽  
Deposition Process ◽  
Processing Parameters ◽  
Laser Deposition ◽  
Filler Wire ◽  
Fiber Laser Welding ◽  
Heat Treated ◽  
Direct Laser ◽  
Wire Feed

In this work, a continuous wave fiber laser welding system was used to deposit nickel-based superalloys Inconel 718 (IN 718) and Waspaloy using filler wire feed sources. The multi-bead and multi-layer deposits that were manufactured were characterized in terms of the macro- and microstructures, defects, and hardness in both the as-deposited and fully heat treated conditions. The tensile properties of the deposits in the heat treated condition were also determined and compared to the existing aerospace materials specifications. Using optimized laser processing parameters, high strength deposits could be manufactured, though minor weld metal liquation cracking for IN718 and strain-age cracking for Waspaloy were present, which compromised slightly the ductility as compared to wrought aerospace specifications for the two alloys. The successful development of the direct laser deposition process using wire feeding indicates the potential of employing the fiber laser technology to manufacture nickel-based superalloy aerospace components.

scholarly journals Effect of the Addition of Nitrogen through Shielding Gas on TIG Welds Made Homogenously and Heterogeneously on 300 Series Austenitic Stainless Steels

2021 ◽  
Vol 5 (3) ◽  
pp. 72
Author(s):  
Rohit Kshirsagar ◽  
Steve Jones ◽  
Jonathan Lawrence ◽  
Jamil Kanfoud
Keyword(s):  
Fatigue Life ◽  
Stainless Steels ◽  
Feed Rate ◽  
Welding Process ◽  
Austenitic Stainless Steels ◽  
Interaction Effects ◽  
Bead Geometry ◽  
Filler Wire ◽  
Shielding Gas ◽  
Wire Feed

Tungsten inert gas (TIG) welding of austenitic stainless steels is a critical process used in industries. Several properties of the welds must be controlled depending on the application. These properties, which include the geometrical, mechanical and microstructural features, can be modified through an appropriate composition of shielding gas. Researchers have studied the effects of the addition of nitrogen through the shielding gas; however, due to limited amount of experimental data, many of the interaction effects are not yet reported. In this study, welds were made homogeneously as well as heterogeneously with various concentrations of nitrogen added through the shielding gas. The gas compositions used were 99.99%Ar (pure), 2.5% N2 + Ar, 5% N2 + Ar and 10% N2 + Ar. Additionally, the welding process parameters were varied to understand different interaction effects between the shielding gas chemistry and the process variables such as filler wire feed rate, welding current, etc. Strong interactions were observed in the case of heterogeneous welds between the gas composition and the filler wire feed rate, with the penetration depth increasing by nearly 30% with the addition of 10% nitrogen in the shielding gas. The interactions were found to influence the bead geometry, which, in turn, had an effect on the mechanical properties as well as the fatigue life of the welds. A nearly 15% increase in the tensile strength of the samples was observed when using 10% nitrogen in the shielding gas, which also translated to a similar increase in the fatigue life.

Static Tensile Strength and Process Optimization of Gas Metal Arc Welding (GMAW) for 1.5 mm Electro-Galvanized Transformation Induced Plasticity 780 (TRIP780) Steel Joint for Automotive Body Structural Applications

2009 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Cindy Jiang ◽  
Chris Karas
Keyword(s):  
Tensile Strength ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Lap Joint ◽  
Transformation Induced Plasticity ◽  
Metal Arc Welding ◽  
Static Tensile ◽  
The Wire ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to Heat affected Zones (HAZ) at the weld joint. In this study Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 1.5 mm Electro Galvanized (EG) Transformation Induced Plasticity 780 (TRIP780) to itself was investigated. The objective of the study was to understand the wire feed rate and torch speed influence on lap joint strength. Design of Experiments (DOE) was conducted to understand the wire feed and torch speed influence on tensile strength. Based on the statistical analysis, wire feed rate and torch speed were significant factors on static tensile strength. Two way interaction effect between wire feed and torch speed was significant. Metallurgical properties of the lap joints were evaluated using optical microscopy. No significant drop in hardness at HAZ, however, significant hardening was observed at the base metal and weld fillet interface.

Gas Metal Arc Welding (GMAW) Process Optimization of a 1.4 mm Uncoated Dual Phase 980 (DP980) Joint for Automotive Body Structural Applications

2010 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Adrian Elliott ◽  
Cindy Jiang
Keyword(s):  
Tensile Strength ◽  
Feed Rate ◽  
Arc Welding ◽  
Gas Metal Arc Welding ◽  
Lap Joints ◽  
Lap Joint ◽  
Metal Arc Welding ◽  
Static Tensile ◽  
The Wire ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to heat-affected zone (HAZ) at the weld joint. In this study Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 1.4 mm uncoated DP980 to itself was investigated. The objective of the study was to understand the wire feed rate and torch speed influence on lap joint tensile strength (static and fatigue). A two factor, two level, full factorial design of experiment (DOE) was conducted to understand the wire feed and torch speed influence on tensile and fatigue strength of the welded joints. In order to understand the curvature effect, a center point was also included in the experiment. Based on the statistical analysis, neither factor was significant on static tensile strength, however, a two way interaction between wire feed rate and torch speed was significant on static tensile strength. Metallurgical properties of the lap joints were evaluated using optical microscopy. A significant hardness drop of 40% was observed at the HAZ.

Static Tensile Strength of Gas Metal Arc Welded (GMAW) Joints of Uncoated Dual Phase 600 (DP600) Steels

2008 ◽  
Author(s):  
Ramakrishna Koganti ◽  
Sergio Angotti ◽  
Armando Joaquin ◽  
Cindy Ziang ◽  
Chris Karas
Keyword(s):  
Tensile Strength ◽  
Feed Rate ◽  
Gas Metal Arc Welding ◽  
High Strength Steels ◽  
High Strength ◽  
Lap Joints ◽  
Lap Joint ◽  
Static Tensile ◽  
The Wire ◽  
Wire Feed

With the increasing demand for safety, energy saving and emission reduction, Advanced High Strength Steels (AHSS) have become very attractive steels for automobile makers. The usage of AHSS steels is projected to grow significantly in the next 5–10 years with new safety and fuel economy regulations. These new steels have significant manufacturing challenges, particularly for welding and stamping. Welding of AHSS remains one of the technical challenges in the successful application of AHSS in automobile structures due to Heat affected Zones (HAZ) at the weld joint. In this study Gas Metal Arc Welding (GMAW) of a lap joint configuration consisting of 1.5 mm uncoated DP600 to itself was investigated. The objective of the study was to understand the wire feed rate and torch speed influence on lap joint strength. A two factor, two level, full factorial design of experiment (DOE) was conducted to understand the wire feed and torch speed influence on tensile strength. In order to understand the curvature effect, center point was also considered in the experiment. Based on the statistical analysis, wire feed rate was the only significant factor on static tensile strength. Metallurgical properties of the lap joints were evaluated using optical microscopy. Significant hardness drop of 40% was observed at the HAZ.

Optimization of Laser Welding Parameters in Aluminum Alloy Welding and Development of Quality Monitoring System for Light Weight Vehicle

2012 ◽  
Vol 706-709 ◽  
pp. 2998-3003 ◽  
Author(s):  
Young Whan Park ◽  
Dong Yun Kim
Keyword(s):  
Tensile Strength ◽  
Aluminum Alloy ◽  
Laser Welding ◽  
Monitoring System ◽  
Welding Speed ◽  
Feed Rate ◽  
Laser Power ◽  
Filler Wire ◽  
Weld Quality ◽  
Wire Feed

In this paper laser welding AA5182 of aluminum alloy with AA5356 filler wire were performed with respect to laser power, welding speed, and wire feed rate. The experiments showed that the tensile strength of the weld was higher than that of the base material under sufficient heat input conditions. A genetic algorithm was used to optimize process parameters which were the laser power, welding speed, and wire feed rate. To do that, a fitness function was formulated, taking into account weldability and productivity. A factor for the weldabilty used tensile strength estimation model which was made by neural network, and as the productivity, welding speed, and wire feed rate were used. Weld monitoring system for aluminum laser welding with filler wire was constructed through the optical sensors to measure the plasma light intensity. Relationship between monitoring signal and plasma and keyhole behavior according to welding condition was analyzed and it was found that sensor signal could express the information for weld quality. Weld quality estimation algorithm was formulated fuzzy multi feature pattern recognition algorithm using the monitoring signals. Quality prediction system was also developed to apply this algorithm to production line.

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