Application of MIG Welding Process of Mild Steel Wire in Additive Manufacturing

2021 ◽  
Vol 877 ◽  
pp. 73-79
Author(s):  
Pattarawadee Poolperm ◽  
Wasawat Nakkiew ◽  
Nirut Naksuk
Keyword(s):  
Additive Manufacturing ◽  
Steel Wire ◽  
Welding Process ◽  
Feed Speed ◽  
Mig Welding ◽  
Microhardness Testing ◽  
Wire Feed Speed ◽  
Forming Characteristics ◽  
Arc Current ◽  
Wire Feed

The purpose of this study is to investigate the forming characteristics of single-pass Metal Inert Gas (MIG) welding wire for multi-layer additive manufacturing parts. Influences of arc current, arc voltage, arc distances, welding speed, wire feed speed, temperatures and heat input on layer formation were analyzed. The deposition of material by MIG process is controlled by a robot (ABB) controller for constructing walls of rectangular box shape. The samples were measured with a microhardness testing and tensile testing onto the welded bead created by the additive manufacturing technique. It was found that the mechanical properties of microhardness values are between 151.70 to 155.80 HV and the tensile strength values are between 472.71 to 491.12 MPa according to transverse and longitudinal sections of the specimens.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

scholarly journals A Parametric Study of Additive Manufacturing Process: TA6V Laser Wire Metal Deposition

2021 ◽  
pp. 15-20
Author(s):  
Valentine Cazaubon ◽  
Audrey Abi Akle ◽  
Xavier Fischer
Keyword(s):  
Additive Manufacturing ◽  
Laser Power ◽  
Pearson Correlation ◽  
Metal Deposition ◽  
Feed Speed ◽  
New Process ◽  
Wire Feed Speed ◽  
Subtractive Manufacturing ◽  
Working Principle ◽  
Wire Feed

AbstractAdditive Manufacturing has proven to be an economically and industrially attractive process in building or repairing parts. However, the major issue of this new process is to guarantee a mechanical behavior identical to the subtractive manufacturing methodologies. The work, presented in this paper, is centered on the Laser Wire Metal Deposition (LMD-w) method with the metallic alloy TA6V. Its working principle is to fuse a coaxial wire on a substrate with a laser as a heat source. To better understand the interaction between the input parameters (Laser Power, Wire Feed Speed and Tool Speed) and the clad geometry output variables (Height, Width and Contact Angle) and the substrate displacement, we have realized an experimentation. We printed 9 clads according Taguchi’s experimental design. Pearson correlation coefficient and Fisher test performed on the experimental measures showed as main result: Tool Speed is the parameter with the most significant influence on the output variables.

scholarly journals Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts

2020 ◽  
Vol 321 ◽  
pp. 03002
Author(s):  
A. Ayed ◽  
G. Bras ◽  
H. Bernard ◽  
P. Michaud ◽  
Y. Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Feed Speed ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
Wire Feed Speed ◽  
Manufacturing Techniques ◽  
Parameter Ranges ◽  
Wire Arc Additive Manufacturing ◽  
Wire Feed

Arc-wire or laser-wire additive manufacturing seems promising because it allows large parts to be produced with significant deposition rates (ten times higher than powder bed additive manufacturing), for a lower investment cost. These additive manufacturing techniques are also very interesting for the construction or the repair of parts. A versatile 3D printing device using a Wire Arc Additive Manufacturing (WAAM) station or laser device Wire Laser Additive Manufacturing (WLAM) for melting a filler wire is developed to repair and build large titanium parts. The final objectives of the study are to optimize the process parameters to control the dimensional stability, the metallurgical and mechanical properties of the produced parts. In this paper, an experimental study is carried out to determine the first order process parameter ranges (synergic law, laser power, wire feed speed, travel speed) appropriate for these two techniques, for repair or construction parts on Ti-6 Al-4V.

Laser-MIG Hybrid Keyhole Welded 6mm Steel/Aluminum Butt Joints

2019 ◽  
Vol 944 ◽  
pp. 581-592
Author(s):  
Dong Qi Lu ◽  
Li Cui ◽  
Hong Xi Chen ◽  
Yao Qing Chang ◽  
Zhi Bo Peng ◽  
...  
Keyword(s):  
Laser Welding ◽  
Welding Process ◽  
Butt Joint ◽  
Feed Speed ◽  
Welded Steel ◽  
Single Beam ◽  
Beam Laser ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Laser Welding Process

At present, the connection of steel/aluminum joints has been widely used in industrial fields such as aerospace, marine and automotive.Although the joints with excellent performance can be obtained by the solid phase welding methods such as explosion welding and friction welding, the production process is complicated and the efficiency is low, and the practical application is limited.Laser welding has attracted a lot of attention from researchers because of its advantages of high energy density, small welding deformation and fast welding speed.However, in the single-beam laser welding process, there are problems such as high joint assembly precision, excessive energy density, and easy formation of depressions in the weld.The newly developed laser-MIG (Metal Inert Gas) hybrid welding not only retains the advantages of laser welding, but also fully exploits the advantages of MIG welding, improves weld formation, improves the stability of the welding process, and helps solve the single-beam laser welding problems.In this paper, the laser deep penetration welding process of 5.5 mm thick E36 steel and 6 mm thick 5083 aluminum alloy butt joint was studied by laser-MIG composite welding heat source. Compared with the single laser welding process, the influence of wire feed speed on the welded steel/aluminum joint, joint interface structure and joint mechanical properties was studied.The results show that the laser-MIG composite deep-melt welding can obtain good steel/aluminum butt joint performance. At a laser power of 3.25 kW, a wire feed speed of 1.5 m / min, a laser offset of 0.5 mm and a defocus of 0 mm, the tensile strength of the steel/aluminum butt joint is as high as 85.0 MPa.Laser-MIG hybrid welding can improve the dent defects of a single laser welded steel/aluminum butt joint. The amount of acicular Fe4Al13 phase in the intermetallic compound was significantly reduced, and the resistance of the steel/aluminum joint was increased from 8.6 kN to 12.7 kN.

The Theoretical and Experimental Investigation into Technological Parameters of High-Melting Metal Arc Spraying

2012 ◽  
Vol 6 (1) ◽  
pp. 60-67 ◽  
Author(s):  
C. H. Li ◽  
S. Wang ◽  
Y. C. Ding
Keyword(s):  
Arc Spraying ◽  
Feed Speed ◽  
High Melting ◽  
Technological Parameters ◽  
Arc Voltage ◽  
Distribution Rules ◽  
Wire Feed Speed ◽  
Arc Current ◽  
Speed Adjustment ◽  
Wire Feed

The experimental study is done for technological parameters of high-melting metal arc spraying to study the influence of spraying current, spraying voltage and wire feed voltage on spraying arc and the influence of spraying current on coating temperature and analyze theoretically the distribution rules of spray gun jet speed field and temperature field and their influencing factors. The results showed that the arc current increases along with arc voltage increase. The lower the spraying voltage is, the smaller the molten grain size becomes. However, if the arc voltage is lower than the minimum critical arc voltage of the material, the arc could not keep smooth burning. The spraying current has correspondence relationship with wire feed speed. The spraying current could be adjusted through wire feed speed adjustment.

scholarly journals Additive Manufacturing of Ti6Al4V with Wire Laser Metal Deposition Process

2021 ◽  
Vol 1016 ◽  
pp. 24-29
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Deposition Process ◽  
Travel Speed ◽  
Beam Power ◽  
Feed Speed ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Growth Prospects ◽  
Wire Feed

Additive manufacturing (AM) using wire as an input material is currently in full swing, with very strong growth prospects thanks to the possibility of creating large parts, with high deposition rates, but also a low investment cost compared to the powder bed fusion machines. A versatile 3D printing device using a Direct Energy Deposition Wire-Laser (DED-W Laser) with Precitec Coaxprinter station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters. The geometrical and metallurgical of produced parts are analyzed. In the literature, several authors agree to define wire feed speed, travel speed, and laser beam power as first-order process parameters governing laser-wire deposition. This study shows the relative importance of these parameters taking separately as well as the importance of their sequencing at the start of the process. Titanium deposit are obtained with powers never explored in bibliography (up to 5 kW), and wire feed speed up to 5 m.min-1 with a complete process repeatability.

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