Effect of Interpass Temperature on Wire Arc Additive Manufacturing Using High-Strength Metal-Cored Wire

Zhai, Wengang; Wu, Naien; Zhou, Wei

doi:10.3390/met12020212

Cited by 30 publications

(4 citation statements)

References 25 publications

(27 reference statements)

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“…Maintaining the interpass temperature within a suitable range is crucial when influencing microstructures and mechanical properties. There have been studies on a variety of different alloys related to the effect of interpass temperature in WAAM on grain size, phase constitution, and mechanical properties [17][18][19][20][21]. In our work, a pyrometer Metis M318 was used to keep the interpass temperature of the walls below 200 • C. Initially, a single-bead wall, 100 mm in length, was printed for 3 layers in order to screen the processing parameters (i.e., WFS and TS) in the medium-to-high production domain and in turn to ensure a high-quality build free of waviness and with other types of defects kept to a minimum by scanning electron microscopy (Figure 1a).…”

Section: Process Parameter Developmentmentioning

confidence: 99%

Microstructures and Corrosion Properties of Wire Arc Additive Manufactured Copper–Nickel Alloys

Song,

Jimenez,

et al. 2024

Materials

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The 70/30 copper–nickel alloy is used mainly in critical parts with more demanding conditions in marine settings. There is a need for innovative methods that offer fast production and cost-effectiveness in order to supplement current copper–nickel alloy manufacturing processes. In this study, we employ wire arc additive manufacturing (WAAM) to fabricate the 70/30 copper–nickel alloy. The as-built microstructure is characterized by columnar grains with prominent dendrites and chemical segregation in the inter-dendritic area. The aspect ratio of the columnar grain increases with increasing travel speed (TS) at the same wire feed speed (WFS). This is in contrast with the equiaxed grain structure, with a more random orientation, of the conventional sample. The sample built with a WFS of 8 m/min, TS of 1000 mm/min, and a track distance of 3.85 mm exhibits superior corrosion properties in the 3.5 wt% NaCl solution when compared with the conventional sample, as evidenced by a higher film resistance and breakdown potential, along with a lower passive current density of the WAAM sample. The corrosion morphology reveals the critical roles played by the nickel element that is unevenly distributed between the dendrite core and inter-dendritic area.

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Section: Process Parameter Developmentmentioning

confidence: 99%

Microstructures and Corrosion Properties of Wire Arc Additive Manufactured Copper–Nickel Alloys

Song,

Jimenez,

et al. 2024

Materials

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“…Yang et al [18] found that increasing the inter-layer cooling time decreases the height variation in the thin walls, however, excessive dwell time cannot decrease the heat accumulation efficiently and will make the deposition process time-consuming. Maintaining a steady interpass temperature between two consecutive layers resulted in homogeneous microstructure and mechanical properties for HSLA steel walls [19].…”

Section: Bead Height Referencesmentioning

confidence: 99%

Modeling and optimization of height-related geometrical parameters for thin wall structures manufactured by metal additive manufacturing

Dehaghani,

Tang,

Panicker

et al. 2023

Int J Adv Manuf Technol

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Cold metal transfer wire arc additive manufacturing (CMT-WAAM) has attracted attention in recent years due to its ability to print walls with higher dimensional accuracy than regular WAAM. To print near net shape parts by CMT-WAAM, there is a need to define a set of height-related geometrical parameters (HGPs) that can capture, quantify, and compare the quality of the height of the produced parts. In the presenting study a set of HGPs, namely, the average height error (AHE), maximum height variation (MHV), and average absolute slope (AAS) are defined and assessed. Fifteen single-track multi-layer walls are printed to check the effect of process parameters on the defined HGPs. It is found that the stability and quality of the print cannot be guaranteed by checking the visual appearance of the single beads and at least five-to-ten-layer walls should be printed. It is also found that the travel speed (TS) and wire feed speed (WFS) have positive monotonic relationships with AAS and MHV, respectively. Correlations between process parameters and HGPs are modeled and optimized using multi-objective optimization and a validation test is performed to check the validity of the developed models. Moreover, HGPs of walls printed using unidirectional and bidirectional path strategies are calculated and compared. Defined HGPs

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“…Though, depending on its geometry, the metallic deposition planning stage has a signi cant impact on the performance of the component produced by WAAM. Some methods to guarantee the geometric precision and adequate mechanical properties of manufactured parts are the use of deposition trajectories that avoid thermal distortions or other geometric defects like pores [17], and the thermal monitoring and control of the component during its manufacturing process [7,[18][19][20]. The heat generated can be dissipated by conduction through the structure and substrate, by forced convection by the shielding gas, or by radiation to the environment.…”

Section: Introductionmentioning

confidence: 99%

Thermal and Microstructural Analysis of Intersections Manufactured by Wire Arc Additive Manufacturing (WAAM)

Sousa,

Coelho,

Júnior

et al. 2023

Preprint

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The Wire Arc Additive Manufacturing (WAAM) stands out in manufacturing metallic structures due to its great potential for application in industry for automated production of parts with large dimensions and considerable geometric complexity. Thus, this work studied the thermal behavior of the material deposited (AWS ER80S-G) in an intersection and its influence on the microstructure. Thermal analysis showed that the cooling rate at the intersection is a little lower than that of a flat wall. The evaluation of the cooling curves in a CCT diagram of the steel indicated the microstructure formed, which was later confirmed by a metallographic analysis. The microstructure was quite similar between the intersection and the flat wall, but there was a significant difference in the transverse direction of deposition, ranging from the morphology of acicular grains at the base and top to equiaxed grains in the intermediate region (ASTM size 9). This difference in microstructure was significant for the hardness of the material according to the deposited layer, however, there were few differences between the intersection and the flat wall. Therefore, there were observed no significant differences between these regions concerning the microstructure or cooling rate, with the variances observed in the hardness being more significant only in the last layers deposited.

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Effect of Interpass Temperature on Wire Arc Additive Manufacturing Using High-Strength Metal-Cored Wire

Cited by 30 publications

References 25 publications

Microstructures and Corrosion Properties of Wire Arc Additive Manufactured Copper–Nickel Alloys

Microstructures and Corrosion Properties of Wire Arc Additive Manufactured Copper–Nickel Alloys

Modeling and optimization of height-related geometrical parameters for thin wall structures manufactured by metal additive manufacturing

Thermal and Microstructural Analysis of Intersections Manufactured by Wire Arc Additive Manufacturing (WAAM)

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