scholarly journals Study of the Impact of the Synergic Line and the Strategy of Conception on Ti-6Al-4V Wire Arc Additive Manufacturing Process (WAAM-CMT)

2021 ◽  
Vol 1016 ◽  
pp. 250-255
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Travel Speed ◽  
Feed Speed ◽  
Thin Walls ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Manufacturing Technologies ◽  
The Impact ◽  
Wire Arc Additive Manufacturing

In additive manufacturing, technologies based on the fusion of a metallic wire using an electric arc represent an interesting alternative to current manufacturing processes, particularly for large metal parts, thanks to higher deposition rates and lower process costs than powder or wire-laser technologies. A versatile 3D printing device using a DED-W Arc (Direct Energy Deposition by wire-arc) station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters and control the geometrical, metallurgical and the mechanical properties of produced parts. In this study, the impact of two different CMT synergic lines on the energetic and geometric behavior of Ti-6Al-4V single deposits is highlighted. These are related to first order parameters: wire feed speed (WFS) and travel speed (TS). The results show difference on energy, geometric of deposits and different deposition regime between these two law with identical process parameters. The second part of this study focuses on the transition from single deposits to walls and blocks. By first choosing the best set of process parameters to make the construction of thin walls (composed of stacked layers), and then the research the optimal horizontal step of deposition (overlapping) for thicker constructions, results obtained made it possible to validate transition from single deposits (1D) to thick walls (3D) without any weld pool collapse or lack of fusion.

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.

Process Development for a Robotized Laser Wire Additive Manufacturing

2017 ◽  
Author(s):  
Meysam Akbari ◽  
Yaoyu Ding ◽  
Radovan Kovacevic
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Process Development ◽  
Laser Scanner ◽  
Travel Speed ◽  
Main Process ◽  
Feed Speed ◽  
Wire Feed Speed ◽  
Deposition Processes ◽  
Complicated Geometries

Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sectors in recent years. Among all metal-based additive techniques, laser metal wire deposition offers some advantages like shorter processing time, more efficient material usage, and a larger buildup envelop. It has been found that robotized laser/wire additive manufacturing (RLWAM) is a demanding process. A plethora of process parameters must be controlled compared to other laser-based metal deposition processes. The influence of main process parameters such as laser power, stepover increment, wire feed speed, travel speed and z-increment was investigated in this study to find the optimal values. Droplet formation, wire dripping, irregular deposition in the first layer, and deviation of the wire tip were also found to be the main obstacles throughout the process and practical solutions were proposed to deal with these issues. In this study, an 8-axis robot (6-axis arm robot with a 2-axis positioner) and a 4 kW fiber laser along with a wire feeder were integrated to print the different geometrical shapes in 3D. In order to verify the geometrical accuracy of the as-built part, the buildup was scanned using a portable 3D laser scanner. The 3D representation, the Standard Tessellation Language (STL) format obtained from the buildup, was compared with the original CAD model. The results show that RLWAM can be successfully applied in printing even complicated geometries.

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.

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.

Direct fabrication of inclined thin-walled parts by exploiting inherent overhanging capability of CMT process

2019 ◽  
Vol 26 (3) ◽  
pp. 499-508
Author(s):  
Yun Zhao ◽  
Fang Li ◽  
Shujun Chen ◽  
Zhenyang Lu
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
Travel Speed ◽  
Statistical Prediction ◽  
Feed Speed ◽  
Auxiliary Equipment ◽  
Content Type ◽  
Geometrical Features ◽  
Thin Walled ◽  
Wire Arc Additive Manufacturing

Purpose The purpose of this paper is to develop a build strategy for inclined thin-walled parts by exploiting the inherent overhanging capability of the cold metal transfer (CMT) process, which release wire-arc additive manufacturing from tedious programming work and restriction of producible size of parts. Design/methodology/approach Inclined thin-walled parts were fabricated with vertically placed welding torch free from any auxiliary equipment. The inclined features were defined and analyzed based on the geometrical model of inclined parts. A statistical prediction model was developed to describe the dependence of inclined geometrical features on process variables. Based on these models, a build strategy was proposed to plan tool path and output process parameters. After that, the flow work was illustrated by fabricating a vase part. Findings The formation mechanism and regulation of inclined geometrical features were revealed by conducting experimental trials. The inclined angle can be significantly increased along with the travel speed and offset distance, whereas the wall width is mainly dependent on the ratio of wire feed speed to travel speed. In contrast to other welding process, CMT has a stronger overhanging capability, which provides the possibility to fabricate parts with large overhanging features directly with high forming accuracy. Originality/value This paper describes a novel build strategy for inclined thin-walled parts free from any auxiliary equipment. With the proposed strategy, a complex structural component can be deposited directly in the rectangular coordinates additive manufacturing system, indicating infinite possibilities on the producible size of the parts. Moreover, equipment requirements and tedious program work can also be significantly reduced.

scholarly journals Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM

2021 ◽  
Author(s):  
Felipe Ribeiro Teixeira ◽  
Fernando Matos Scotti ◽  
Louriel Oliveira Vilarinho ◽  
Carlos Alberto Mendes da Mota ◽  
Américo Scotti
Keyword(s):  
Surface Finish ◽  
Steel Wire ◽  
Travel Speed ◽  
Parameter Selection ◽  
Basic Material ◽  
Feed Speed ◽  
Thin Wall ◽  
Wall Width ◽  
Thin Walls ◽  
Wire Feed Speed

AbstractThis work aims to propose and assess a methodology for parameterization for WAAM of thin walls based on a previously existing working envelope built for a basic material (parameter transferability). This work also aimed at investigating whether the working envelope approach can be used to optimize the parameterization for a target wall width in terms of arc energy (which governs microstructure and microhardness), surface finish and active deposition time. To reach the main objective, first, a reference working envelope was developed through a series of deposited walls with a plain C-Mn steel wire. Wire feed speed (WFS) and travel speed (TS) were treated as independent variables, while the geometric wall features were considered dependent variables. After validation, three combinations of WFS and TS capable of achieving the same effective wall width were deposited with a 2.25Cr-1Mo steel wire. To evaluate the parameter transferability between the two materials, the geometric features of these walls were measured and compared with the predicted values. The results showed minor deviations between the predicted and measured values. As a result, WAAM parameter selection for another material showed to be feasible after only fewer experiments (shorter time and lower resource consumption) from a working envelope previously developed. The usage of the approach to optimize parameterization was also demonstrated. For this case, lower values of WFS and TS were capable of achieving a better surface finish. However, higher WFS and TS are advantageous in terms of production time. As long as the same wall width is maintained, variations in WFS and TS do not significantly affect microstructure and microhardness.

scholarly journals Process Parameters Effect on Weld Beads Geometry Deposited by Wire and Arc Additive Manufacturing (WAAM)

2021 ◽  
pp. 9-14
Author(s):  
Supasit Manokruang ◽  
Frederic Vignat ◽  
Matthieu Museau ◽  
Maxime Limousin
Keyword(s):  
Additive Manufacturing ◽  
Substrate Temperature ◽  
Process Parameters ◽  
Welding Parameters ◽  
Bead Geometry ◽  
Weld Bead Geometry ◽  
Cold Metal Transfer ◽  
Wire Feed Speed ◽  
Manufacturing Technologies ◽  
Cold Metal

AbstractAmong Additive Manufacturing technologies, Wire and Arc Additive Manufacturing process is strongly dependent of deposition conditions such as welding parameters, substrate temperature, trajectory. In this research, geometry and temperature evolutions of single beads have been investigated according to process parameters modifications. For our experiment, a heating device have been used in order to control the substrate temperature from room temperature up to 400 °C. Considering the Cold Metal Transfer technology, welding parameters, Wire Feed Speed (WFS) and Travel Speed (TS), have been modified while keeping a constant ratio λ (WFS/TS). Results indicate that weld bead geometry, height (h) and width (w), is influenced by substrate temperature and welding parameters. It has been shown that substrate temperature, itself influenced by process parameters, tends to produce thicker and lower weld beads while it increases.

scholarly journals Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

2021 ◽  
Vol 11 (10) ◽  
pp. 4694
Author(s):  
Christian Wacker ◽  
Markus Köhler ◽  
Martin David ◽  
Franziska Aschersleben ◽  
Felix Gabriel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Welding Process ◽  
High Energy ◽  
Welding Distortion ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Industrial Use ◽  
Artificial Neural ◽  
Artificial Neural Network Ann ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

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.

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