Effect of heat input on microstructure and mechanical property of wire-arc additive manufactured Ti-6Al-4V alloy

Guo, Xian; Oh, Jeong Mok; Lee, Junghoon; Cho, Sang Myung; Yeom, Jong-Tak; Choi, Yoonsuk; Kang, Ning

doi:10.1007/s40194-021-01248-3

Cited by 23 publications

(4 citation statements)

References 28 publications

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“…The secondary α phase in martensite is mainly formed in repeated cycles. Xian et al [ 32 ] reported that the rapid cooling rate would lead to fine α s phase, and the martensite and additional α s phase increased the strength. However, the large heat input of WAAM will cause a large range of heat‐affected zone (HAZ) on the Nth layer when the N + 1 layer is deposited, which will produce the intrinsic heat treatment effect on the Nth layer.…”

Section: Discussionmentioning

confidence: 99%

Effect of Interlayer‐Compressed Argon Gas Active Cooling on Microstructure and Properties of Ti–6Al–4V Fabricated by WAAM

Zhang

Zhou

et al. 2023

Adv Eng Mater

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WAAM (Wire Arc Additive Manufacturing) has been widely used due to its advantages of high processing freedom, low cost and high efficiency. However, one of the most relevant unsolved problems in WAAM is the heat accumulation caused by high heat input. In this study, the compressed argon‐based interlayer AC (Active Cooling) process is employed to reduce heat accumulation, and the influence mechanism on microstructure and mechanical properties of Ti‐6Al‐4V samples were revealed. The results show that the introduction of interlayer AC leads to the interlayer temperature decreases from 468 °C to 53 °C, and the widths of prior‐β columnar grains and αGB are refined. The increase of cooling rate (380 °C/s → 604 °C/s) results in the transformation of large‐sized colonies into finer basketweave structure, accompanied by the production of martensite α’ and a slight increase of β phase content. The finer basketweave structure increase the strength of the samples, while the narrower αGB and the high‐angle grain boundaries increase the resistance of crack propagation. The high dislocation density caused by the faster cooling rate increases the plastic deformation of the AC samples to a certain extent. As a result, the interlayer AC improves the strength and plasticity of the samples simultaneously, the samples change from brittle and ductile mixed fracture to ductile fracture mode.This article is protected by copyright. All rights reserved.

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Section: Discussionmentioning

confidence: 99%

Effect of Interlayer‐Compressed Argon Gas Active Cooling on Microstructure and Properties of Ti–6Al–4V Fabricated by WAAM

Zhang

Zhou

et al. 2023

Adv Eng Mater

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“…The process utilized a deposition rate of about 3.3 kg/h, an energy per length of about 10 6 J/m, an average power of 6 kW, and a travel speed of about 5–6 mm/s. The process parameters used for manufacturing are comparable to data from the literature [ 16 ]. To protect the melted weld pool and the heat-affected zone from oxidation and other undesirable contamination, a pure argon-filled box chamber was used.…”

Section: Methodsmentioning

confidence: 99%

Low-Cycle Fatigue Behavior of Wire and Arc Additively Manufactured Ti-6Al-4V Material

Springer,

Leitner,

Gruber

et al. 2023

Materials

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Additive manufacturing (AM) techniques, such as wire arc additive manufacturing (WAAM), offer unique advantages in producing large, complex structures with reduced lead time and material waste. However, their application in fatigue-critical applications requires a thorough understanding of the material properties and behavior. Due to the layered nature of the manufacturing process, WAAM structures have different microstructures and mechanical properties compared to their substrate counterparts. This study investigated the mechanical behavior and fatigue performance of Ti-6Al-4V fabricated using WAAM compared to the substrate material. Tensile and low-cycle fatigue (LCF) tests were conducted on both materials, and the microstructure was analyzed using optical microscopy and scanning electron microscopy (SEM). The results showed that the WAAM material has a coarser and more heterogeneous grain structure, an increased amount of defects, and lower ultimate tensile strength and smaller elongation at fracture. Furthermore, strain-controlled LCF tests revealed a lower fatigue strength of the WAAM material compared to the substrate, with crack initiation occurring at pores in the specimen rather than microstructural features. Experimental data were used to fit the Ramberg–Osgood model for cyclic deformation behavior and the Manson–Coffin–Basquin model for strain-life curves. The fitted models were subsequently used to compare the two material conditions with other AM processes. In general, the quasi-static properties of WAAM material were found to be lower than those of powder-based processes like selective laser melting or electron beam melting due to smaller cooling rates within the WAAM process. Finally, two simplified estimation models for the strain-life relationship were compared to the experimentally fitted Manson–Coffin–Basquin parameters. The results showed that the simple “universal material law” is applicable and can be used for a quick and simple estimation of the material behavior in cyclic loading conditions. Overall, this study highlights the importance of understanding the mechanical behavior and fatigue performance of WAAM structures compared to their substrate counterparts, as well as the need for further research to improve the understanding of the effects of WAAM process parameters on the mechanical properties and fatigue performance of the fabricated structures.

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“…In 2022, the influence of heat input on the microstructure and mechanical properties of the deposited Ti-6Al-4V alloy was investigated [22]. The study found that high heat input (10 6 J/m) resulted in columnar grains exhibiting significant anisotropic tensile strength.…”

Section: Introductionmentioning

confidence: 99%

The Engine Casing Machining Holes Repairing Based on Vibration Wire Feeding

Pan,

Gao,

et al. 2024

Metals

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The engine casing components operate in high-temperature and high-pressure environments. Process holes are drilled when defects occur. Welding is employed in the repair of process holes as a process for permanently joining materials. The traditional welding method relies on padding, which results in poor back formation of process holes. Additionally, the shape of the process holes imposes high requirements on the size of the droplet transition. The conventional approach of adjusting a welding current makes it difficult to achieve stable droplet transition and precise formation of small holes. It poses a challenge for the robotic welding process. To deal with this problem, the influence of the high-frequency vibration GTAW process on the directional transition of molten droplets is studied. The molten droplet directional transition process is developed. The impact of vibration energy on the molten pool is reduced. Welding repair experiments for process holes are successfully conducted. When the frequency is 3 Hz, the transition of droplets changes from a continuous one-droplet transition to a discontinuous liquid bridge transition. The residual height and mechanical properties of the repaired area are tested. The experimental results indicated that the residual height after dual-side repair is ≤0.7 mm. The X-ray and fluorescent penetration tests have a 100% first-pass qualification rate. The repaired area demonstrates a hardness of 480 HV and a room-temperature tensile strength of 1069 MPa. The repair process requirements for the casing are met.

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Effect of heat input on microstructure and mechanical property of wire-arc additive manufactured Ti-6Al-4V alloy

Cited by 23 publications

References 28 publications

Effect of Interlayer‐Compressed Argon Gas Active Cooling on Microstructure and Properties of Ti–6Al–4V Fabricated by WAAM

Effect of Interlayer‐Compressed Argon Gas Active Cooling on Microstructure and Properties of Ti–6Al–4V Fabricated by WAAM

Low-Cycle Fatigue Behavior of Wire and Arc Additively Manufactured Ti-6Al-4V Material

The Engine Casing Machining Holes Repairing Based on Vibration Wire Feeding

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