A Brief Review on The Common Defects in Wire Arc Additive Manufacturing

Albannai, Abdulaziz I.

doi:10.47191/ijcsrr/v5-i12-19

Cited by 4 publications

(22 citation statements)

References 94 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The lack of fusion is caused by insufficient overlap between passes. Some causes include low energy input, an improper torch angle, an inappropriate weld position, and insufficient filler wire material, among others [ 97 ].…”

Section: General Welding Problems For Aluminum Alloysmentioning

confidence: 99%

See 1 more Smart Citation

Wire Arc Additive Manufacturing (WAAM) for Aluminum-Lithium Alloys: A Review

2023

View full text Add to dashboard Cite

Out of all the metal additive manufacturing (AM) techniques, the directed energy deposition (DED) technique, and particularly the wire-based one, are of great interest due to their rapid production. In addition, they are recognized as being the fastest technique capable of producing fully functional structural parts, near-net-shape products with complex geometry and almost unlimited size. There are several wire-based systems, such as plasma arc welding and laser melting deposition, depending on the heat source. The main drawback is the lack of commercially available wire; for instance, the absence of high-strength aluminum alloy wires. Therefore, this review covers conventional and innovative processes of wire production and includes a summary of the Al-Cu-Li alloys with the most industrial interest in order to foment and promote the selection of the most suitable wire compositions. The role of each alloying element is key for specific wire design in WAAM; this review describes the role of each element (typically strengthening by age hardening, solid solution and grain size reduction) with special attention to lithium. At the same time, the defects in the WAAM part limit its applicability. For this reason, all the defects related to the WAAM process, together with those related to the chemical composition of the alloy, are mentioned. Finally, future developments are summarized, encompassing the most suitable techniques for Al-Cu-Li alloys, such as PMC (pulse multicontrol) and CMT (cold metal transfer).

show abstract

Section: General Welding Problems For Aluminum Alloysmentioning

confidence: 99%

“…This is due to low energy input. However, other causes of delamination by WAAM are residual stresses and contamination of parts or substrate surfaces [ 97 , 98 ].…”

Section: General Welding Problems For Aluminum Alloysmentioning

confidence: 99%

Wire Arc Additive Manufacturing (WAAM) for Aluminum-Lithium Alloys: A Review

2023

View full text Add to dashboard Cite

show abstract

“…Porosity defects in WAAM are small holes, voids, or pores throughout the structure, as shown in Figure 1. indicating the presence of pores (on surface and inside the part) and lack of fusion, adapted from [3]. (b) Pores in a weld bead identified with an X-ray test, adapted from [4].…”

Section: Porositymentioning

confidence: 99%

“…Reduced strength and durability [3]: Porosity defects can weaken the structural integrity of the printed part, making it less durable and more susceptible to failure under load. This can be particularly problematic for parts that are intended to be used in high-stress or high-load applications.…”

mentioning

confidence: 99%

Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Serrati

Machado

Oliveira

et al. 2023

Metals

View full text Add to dashboard Cite

The wire and arc additive manufacturing (WAAM) process enables the creation and repair of complex structures based on the successive deposition of fed metal in the form of a wire that is fused with an electric arc and then solidifies. The high number of depositions required to create or repair parts increases the likelihood of defect formation. If these are reliably detected during manufacturing, timely correction is possible. However, high temperatures and surface irregularity make inspection difficult. Furthermore, depending on the size, morphology, and location of the defect, the part can be rejected. Recent studies have shown that non-destructive testing (NDT) based on different physical phenomena for the timely, reliable, and customized detection of defects can significantly reduce the rejection rate and allow in-line repair, which consequently reduces waste and rework. This paper presents the latest developments in NDT for WAAM and its limitations and potential.

show abstract

“…The interfacial properties between the substrate and the deposited material also influence the final component quality during repair procedures [7,39,40]. During repair work, the boundary properties between the substrate and deposited material are prone to flaws, causing failure during operation [22,41].…”

Section: Introductionmentioning

confidence: 99%

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Kachomba,

Mutua,

Obiko

et al. 2024

Mater. Res. Express

View full text Add to dashboard Cite

Wire-arc additive manufacturing (WAAM) has emerged as a critical tool for remanufacturing industrial components. A limited understanding of this technique for quality product manufacturing has hindered its utilisation for industrial applications. This study reports on the optimisation of WAAM process parameters for AISI 4130 steel towards remanufacturing of high-quality products for industrial applications. AISI 4130 steel was selected for this study due to its high strength-to-weight ratio, excellent weldability, and suitability for the WAAM process. Taguchi’s Grey Relational Analysis (GRA) used four factors and three levels in the multiple response optimisation process. The study considered process parameters voltage, current, travel speed and gas flow in the gas metal arc welding (GMAW)-based WAAM technique. Analysis of Variance (ANOVA) results show that voltage, travel speed and gas flow significantly affect material deposition. Voltage had the highest significance (31.61%) compared to other parameters. The optimised process parameters were found to be: voltage - 23V, current - 100A, travel speed - 350mm/min, and gas flow - 10L/min. These parameters resulted in tensile residual stresses of 25 ±74 MPa, microhardness of 171.4±12.2 HV0.3, and a relative density of 98.21%. The microstructural analysis reveals existence of predominant ferritic and pearlitic colonies. This is due to compounded thermal stresses during the deposition process and alloy composition resulting in tailored microstructure and mechanical properties. The study provides some insights into the WAAM remanufacturing process for producing highly quality industrial components.

show abstract

A Brief Review on The Common Defects in Wire Arc Additive Manufacturing

Cited by 4 publications

References 94 publications

Wire Arc Additive Manufacturing (WAAM) for Aluminum-Lithium Alloys: A Review

Wire Arc Additive Manufacturing (WAAM) for Aluminum-Lithium Alloys: A Review

Non-Destructive Testing Inspection for Metal Components Produced Using Wire and Arc Additive Manufacturing

Multi-response optimisation of wire-arc additive manufacturing process parameters for AISI 4130 steel during remanufacturing process

Contact Info

Product

Resources

About