Characterization of robotized CMT-WAAM carbon steel

Tankova, Trayana; Andrade, David C.; Branco, R.; Zhu, Carlos Ye; Rodrigues, D.M.; Silva, Luís Simões da

doi:10.1016/j.jcsr.2022.107624

Cited by 31 publications

(11 citation statements)

References 25 publications

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“…The high-temperature gradient is responsible for rapid heat dissipation that does not allow sufficient time for grain growth and results in fine equiaxed grains near the bottom region of the WAAM-fabricated part. A similar grain morphology in the bottom layers was also reported in several other studies of ER70S-6 WAAM printed walls (Nagasai et al , 2022; Tankova et al , 2022). However, as the number of deposited layers increases, around the middle region of the printed parts, the cooling rate becomes relatively slower and the dissipation of heat energy is hindered.…”

Section: Resultssupporting

confidence: 88%

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Kumar,

Mandal

2024

RPJ

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Purpose Wire-arc-based additive manufacturing (WAAM) is a promising technology for the efficient and economical fabrication of medium-large components. However, the anisotropic behavior of the multilayered WAAM-fabricated components remains a challenging problem. Design/methodology/approach The purpose of this paper is to conduct a comprehensive study of the grain morphology, crystallographic orientation and texture in three regions of the WAAM printed component. Furthermore, the interdependence of the grain morphology in different regions of the fabricated component with their mechanical and tribological properties was established. Findings The electron back-scattered diffraction analysis of the top and bottom regions revealed fine recrystallized grains, whereas the middle regions acquired columnar grains with an average size of approximately 8.980 µm. The analysis revealed a higher misorientation angle and an intense crystallographic texture in the upper and lower regions. The investigations found a higher microhardness value of 168.93 ± 1.71 HV with superior wear resistance in the bottom region. The quantitative evaluation of the residual stress detected higher compressive stress in the upper regions. Evidence for comparable ultimate tensile strength and greater elongation (%) compared to its wrought counterpart has been observed. Originality/value The study found a good correlation between the grain morphology in different regions of the WAAM-fabricated component and their mechanical and wear properties. The Hall–Petch relationship also established good agreement between the grain morphology and tensile test results. Improved ductility compared to its wrought counterpart was observed. The anisotropy exists with improved mechanical properties along the longitudinal direction. Moreover, cylindrical components have superior tribological properties compared with cuboidal components.

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Section: Resultssupporting

confidence: 88%

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Kumar,

Mandal

2024

RPJ

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“…The study of AM materials' properties is still in its early stages. Nevertheless, promising results have been found in the latest research, matching or even surpassing the behaviour of conventional hot-rolled or forged steels [11]. A similar conclusion can be stated for the study of its fatigue cyclic properties, highly relevant in the field of wind towers [12,13].…”

Section: Additive Manufacturingsupporting

confidence: 58%

“…In order to achieve this, the optimised shapes were extracted from Tosca Structure as an input file and brought back to Abaqus/CAE to run a numerical analysis, now using a plastic material model obtained from laboratory experiments and considering geometric non-linearities [11].…”

Section: Finite Element Analysismentioning

confidence: 99%

Additive Manufacturing of a Steel Splice Joint for Tubular Elements in a Modular Wind Tower

Morales,

Tankova,

Branco

et al. 2023

ce papers

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Wind turbines of large size pose a challenge to structural engineers in providing suitable supporting structures. Nevertheless, these structures frequently result in complex logistical requirements, raising the expenses of new projects. Hence, the design philosophy is shifting towards lighter and modular towers, which often use tubular components. However, due to the intricate shape of the joints, connecting these tubular components is costly and laborious. Therefore, considering the advantages of new fabrication techniques, such as additive manufacturing, a ‘plug and play’ (PnP) device is in development to satisfy the requirements of a splice joint part of an onshore modular tower supporting a wind energy converter. An optimisation methodology was developed to determine the geometry of the device by structural topology optimisation and validate using finite element method software. As result from this methodology, three optimised geometries able to meet the desired requirements were found. Finally, the PnP device delivered a bespoke solution that allows for the simple joining of modular tubular components and reduces the raw material consumption without compromising the performance of the joint.

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“…A constant emissivity of 0.65 was applied to determine the temperature evolution throughout the process. This value was determined during the deposition of a wall made of the same material of the lattice structure [ 25 ], by comparing the temperature readings obtained with a thermocouple welded to the wall to those recorded with the thermographic camera, as exemplified in Figure 4 . In the figure, the curves representing the evolution of the temperature at the thermocouple location with time, during the deposition of several material layers, are shown.…”

Section: Methodsmentioning

confidence: 99%

Thermal, Microstructural, and Mechanical Analysis of Complex Lattice Structures Produced by Direct Energy Deposition

Andrade,

Zhu,

Miranda

et al. 2024

Materials

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Lattice structures have gained attention in engineering due to their lightweight properties. However, the complex geometry of lattice structures and the high melting temperature of metals present significant manufacturing challenges for the large-scale fabrication of these structures. Direct Energy Deposition (DED) methods, such as the Wire Arc Additive Manufacturing (WAAM) technique, appear to be an interesting solution for overcoming these limitations. This study provides a detailed analysis of the manufacturing process of carbon steel lattice structures with auxetic geometry. The study includes thermal analysis using infrared thermography, microstructural characterization through metallography, and mechanical evaluation via hardness and mechanical testing. The findings reveal the significant impact of heat input, thermal cycles, and deposition sequence on the morphology and mechanical properties of the lattice structures. Fast thermal cycles are related to areas with higher hardness values, smaller strut diameters, and porous formations, which shows that controlling heat input and heat dissipation is crucial for optimizing the properties of lattice structures produced using WAAM.

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Characterization of robotized CMT-WAAM carbon steel

Cited by 31 publications

References 25 publications

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Additive Manufacturing of a Steel Splice Joint for Tubular Elements in a Modular Wind Tower

Thermal, Microstructural, and Mechanical Analysis of Complex Lattice Structures Produced by Direct Energy Deposition

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