A numerical model-based deposition strategy for heat input regulation during plasma arc-based additive manufacturing

Zheng, Yi; Yu, Zhiyuan; Xie, Jingren; Chen, Junmei; Yu, Chun Pong; Xu, Jijin; Lu, Hao

doi:10.1016/j.addma.2022.102986

Cited by 7 publications

(5 citation statements)

References 28 publications

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“…In the CMT advance-based WAAM process, the molten pool flow was under the action of arc pressure, surface tension, self-induced electromagnetic force, and buoyancy force. The surface tension gradient and shear stress driven by the arc plasma jet played significant roles in the convention of molten pool [20]. The EP CMT cycles and total heat input increased when the high EP/EN ratios were selected.…”

Section: Resultsmentioning

confidence: 99%

“…The EP CMT cycles and total heat input increased when the high EP/EN ratios were selected. The excessive heat input increased the temperature at the centre of the molten pool, which increased the surface tension gradient and strengthened the Marangoni convective during the deposition process [20,21]. This convective motion was detrimental to the stability of the molten pool and forming accuracy during the WAAM process.…”

Section: Resultsmentioning

confidence: 99%

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Process stability and forming accuracy on wire arc additive manufactured Al–Zn–Mg–Cu alloy with different electrode positive/electrode negative ratios of CMT advance process

Wang

Chen

et al. 2023

Science and Technology of Welding and Joining

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The influence of electrode positive/electrode negative (EP/EN) ratio on cold metal transfer advance-based wire arc additive manufacturing (WAAM) process for Al-Zn-Mg-Cu alloy was studied in this paper. The process stability was investigated via analysing electrical waveforms and arc/metal transfer images concurrently. A high EP/EN ratio ( ≥ 13:7) was beneficial to decrease abnormal long wait phase duration of current and spatter of droplet, which improved the stability of WAAM process. The forming accuracies of the samples increased first and then decreased with the increase of EP/EN ratio due to the incompatibility of the heat input and molten pool flow. The average width and effective width coefficient showed a positive correlation with EP/EN ratio.

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Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

Process stability and forming accuracy on wire arc additive manufactured Al–Zn–Mg–Cu alloy with different electrode positive/electrode negative ratios of CMT advance process

Wang

Chen

et al. 2023

Science and Technology of Welding and Joining

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“…17 Illustration of the plasma spraying system [194] Fig. 18 Illustration of the plasma additive manufacturing system on the welding process first, the free surface of the molten pool and solidified bead [199,200] are the essential features to be captured and modeled. The molten pool serves as the origin to decide the deposited bead shape and size in AM driven by the intricate heat transfer and fluid flow interactions in the unstable pool-shaped structure.…”

Section: Additive Manufacturing Modelingmentioning

confidence: 99%

A Review of Simulation Modeling of the State Evaluation and Process Prediction of Plasma Processing under Atmospheric Pressure

Wei,

Mitchell,

Sun

et al. 2024

Nanomanuf Metrol

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In recent decades, interest in simulation modeling of plasma processing under atmospheric pressure has been growing because of its appealing advantages across various domains. These advantages encompass the provision of diverse data types for evaluating processing states, the capability to predict processing outcomes from current operating conditions, and cost-effectiveness in comparison to experimental methods. This paper endeavors to offer a concise review of the evolution of simulation modeling of atmospheric plasma processing. This review encompasses foundational concepts and methodologies of plasma generation modeling of both thermal and nonthermal plasmas, progressing to discuss the framework and challenges of plasma processing modeling. In addition, a brief overview of contemporary challenges in modeling, such as simplifying complex physics, designing computational domains, and optimizing the balance between computational precision and cost, is provided to foster the advancement of atmospheric plasma processing modeling.

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“…Aluminium alloy is widely used in modern industrial sectors, such as aerospace [1], shipbuilding [2], automotive [3], and so on., with its good performances, such as low density, good plasticity, and high corrosion resistance [4], etc. Arc technologies, including MIG (Metal Inert Gas Arc Welding) [5] and PAW (Plasma Arc Welding) [6], etc., are widely applied to welding aluminium alloy by industry due to their outstanding benefits, including high efficiency and flexibility, etc. During aluminium alloy welding, the metal droplets are subjected to the effects of multi-physics fields and thus have different thermodynamic behaviours, which are essential to obtain a stable process and a high-quality joint [7].…”

Section: Introductionmentioning

confidence: 99%

Effects of bypass-current and out plasma current on droplet transfer behaviours during plasma-MIG hybrid arc welding

Miao

Wang

et al. 2023

Science and Technology of Welding and Joining

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A new method, bypass-current plasma-MIG hybrid arc welding, was proposed to weld AA 5083 aluminium alloy. A comparative investigation between simulation and experiment was performed to quantify different effects of bypass-current and out plasma current on droplet transfer behaviours. The results show that when the bypass-current is 15 A, the droplets present a projected transfer mode, and its period is 22 ms. But if the outer plasma current is 15 A, the transfer frequency increases 19.1 Hz, and the sizes of the droplet show a slight increase. This is due to the reduction of electromagnetic force and arc plasma force on droplets. The research outcomes provide benefits to the droplet transfer behaviours in control and optimisation during aluminium alloy welding.

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A numerical model-based deposition strategy for heat input regulation during plasma arc-based additive manufacturing

Cited by 7 publications

References 28 publications

Process stability and forming accuracy on wire arc additive manufactured Al–Zn–Mg–Cu alloy with different electrode positive/electrode negative ratios of CMT advance process

Process stability and forming accuracy on wire arc additive manufactured Al–Zn–Mg–Cu alloy with different electrode positive/electrode negative ratios of CMT advance process

A Review of Simulation Modeling of the State Evaluation and Process Prediction of Plasma Processing under Atmospheric Pressure

Effects of bypass-current and out plasma current on droplet transfer behaviours during plasma-MIG hybrid arc welding

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