Effect of arc mode in cold metal transfer process on porosity of additively manufactured Al-6.3%Cu alloy

Cong, Baoqiang; Ding, Jialuo; Williams, Stewart

doi:10.1007/s00170-014-6346-x

Cited by 396 publications

(171 citation statements)

References 17 publications

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“…It has four different variants, which are standard CMT, CMT-P, CMT-ADV and CMT-P-ADV. As presented in the study of the effects of these different CMT variants on the porosity in the WAAM aluminum thin wall structure [15], adding a pulsing cycle to the standard CMT helps the control of porosity. Compared with the CMT-P process, the CMT-ADV process controls porosity even more efficiently due to its lower heat input, cleaning effect on the tip of the wire during the negative cycle and the smaller microstructure [15].…”

Section: Methodsmentioning

confidence: 99%

“…WAAM Al-6.3%Cu alloy was also studied with the cold metal transfer (CMT) process [13], with a focus of the effect of inter-layer cold working and post-deposition heat treatment on the material strengthening of this alloy [8] and their effect on porosity control [14]. Cong et al [15] found that by using pulse-advanced cold metal transfer (CMT-P-ADV), pore-free deposition with refined equiaxed grains of the WAAM Al-6.3%Cu alloy can be produced.…”

Section: Methodsmentioning

confidence: 99%

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A Comparative Study of Additively Manufactured Thin Wall and Block Structure with Al-6.3%Cu Alloy Using Cold Metal Transfer Process

Cong

et al. 2017

Applied Sciences

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138

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Abstract:In order to build a better understanding of the relationship between depositing mode and porosity, microstructure, and properties in wire + arc additive manufacturing (WAAM) 2319-Al components, several Al-6.3%Cu deposits were produced by WAAM technique with cold metal transfer (CMT) variants, pulsed CMT (CMT-P) and advanced CMT (CMT-ADV). Thin walls and blocks were selected as the depositing paths to make WAAM samples. Porosity, microstructure and micro hardness of these WAAM samples were investigated. Compared with CMT-P and thin wall mode, CMT-ADV and block process can effectively reduce the pores in WAAM aluminum alloy. The microstructure varied with different depositing paths and CMT variants. The micro hardness value of thin wall samples was around 75 HV from the bottom to the middle, and gradually decreased toward the top. Meanwhile, the micro hardness value ranged around 72-77 HV, and varied periodically in block samples. The variation in micro hardness is consistent with standard microstructure characteristics.

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Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

A Comparative Study of Additively Manufactured Thin Wall and Block Structure with Al-6.3%Cu Alloy Using Cold Metal Transfer Process

Cong

et al. 2017

Applied Sciences

Self Cite

138

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“…For example, it is possible to create custom mixes of powders and binders [353], to alternate feedstock materials [81] [357], and to embed fibers [33][65] [67] in order to create in situ composites, increase mechanical strength, modify the thermal expansion coefficient [67], and obtain electrically tuneable stiffness [281]. Similarly, it is possible to control the porosity, microstructure, and material properties of metal, polymer, and ceramic parts through the choice of materials, process parameters, and build orientation [75][292] [353][362] [365].…”

Section: Custom Metallurgy Microstructure and Materials Compositionmentioning

confidence: 99%

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

et al. 2016

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The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry.Design, Manufacturing, Additive Manufacturing

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“…A very interesting paper from Cong et al [25] explores in depth the influence of the arc mode for different CMT variants (CMT, CMT pulse, CMT advanced, and CMT pulse advanced) on the porosity of an aluminum alloy fabricated by WAAM. In this work, CMT pulse advanced showed excellent performance in controlling porosity, being the most suitable variant for depositing aluminum alloys.…”

Section: Introductionmentioning

confidence: 99%

Analysis of Favorable Process Conditions for the Manufacturing of Thin-Wall Pieces of Mild Steel Obtained by Wire and Arc Additive Manufacturing (WAAM)

et al. 2018

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One of the challenges in additive manufacturing (AM) of metallic materials is to obtain workpieces free of defects with excellent physical, mechanical, and metallurgical properties. In wire and arc additive manufacturing (WAAM) the influences of process conditions on thermal history, microstructure and resultant mechanical and surface properties of parts must be analyzed. In this work, 3D metallic parts of mild steel wire (American Welding Society-AWS ER70S-6) are built with a WAAM process by depositing layers of material on a substrate of a S235 JR steel sheet of 3 mm thickness under different process conditions, using as welding process the gas metal arc welding (GMAW) with cold metal transfer (CMT) technology, combined with a positioning system such as a computer numerical controlled (CNC) milling machine. Considering the hardness profiles, the estimated ultimate tensile strengths (UTS) derived from the hardness measurements and the microstructure findings, it can be concluded that the most favorable process conditions are the ones provided by CMT, with homogeneous hardness profiles, good mechanical strengths in accordance to conditions defined by standard, and without formation of a decohesionated external layer; CMT Continuous is the optimal option as the mechanical properties are better than single CMT.

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Effect of arc mode in cold metal transfer process on porosity of additively manufactured Al-6.3%Cu alloy

Cited by 396 publications

References 17 publications

A Comparative Study of Additively Manufactured Thin Wall and Block Structure with Al-6.3%Cu Alloy Using Cold Metal Transfer Process

A Comparative Study of Additively Manufactured Thin Wall and Block Structure with Al-6.3%Cu Alloy Using Cold Metal Transfer Process

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

Analysis of Favorable Process Conditions for the Manufacturing of Thin-Wall Pieces of Mild Steel Obtained by Wire and Arc Additive Manufacturing (WAAM)

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