Evaluation of tandem controlled short-circuit GMAW for improved deposition in additive manufacture of large Nickel Aluminium Bronze naval components

Queguineur, A.; Marolleau, J.; Lavergne, A.; Rückert, Guillaume

doi:10.1007/s40194-020-00925-z

Cited by 13 publications

(10 citation statements)

References 4 publications

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“…Figure 74 compares the macrostructure of the WAAM NAB with and without ultrasonic vibration, confirming the removal of the columnar structure [157]. In a recent study, Queguineur et al [158] attempted to increase the deposition rate and improve the economics of WAAM fabrication of NABs using the tandem method, which involves replacing the single CMT torch with the CMT Twin strategy, as shown in Figure 75. They concluded that the CMT Twin strategy resulted in a wider bed fusion and improved the deposition rate but also led to excessive heat accumulation, resulting in longer cooling times between the layers, which diminished the advantages of employing the tandem method [158].…”

Section: Microstructure Of Waam-produced Nab Alloysmentioning

confidence: 81%

“…In a recent study, Queguineur et al [158] attempted to increase the deposition rate and improve the economics of WAAM fabrication of NABs using the tandem method, which involves replacing the single CMT torch with the CMT Twin strategy, as shown in Figure 75. They concluded that the CMT Twin strategy resulted in a wider bed fusion and improved the deposition rate but also led to excessive heat accumulation, resulting in longer cooling times between the layers, which diminished the advantages of employing the tandem method [158]. Therefore, they suggested using the CMT Twin method for large In a recent study, Queguineur et al [158] attempted to increase the deposition rate and improve the economics of WAAM fabrication of NABs using the tandem method, which involves replacing the single CMT torch with the CMT Twin strategy, as shown in Figure 75.…”

Section: Microstructure Of Waam-produced Nab Alloysmentioning

confidence: 99%

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Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review

Vahedi Nemani,

Ghaffari,

Sabet Bokati

et al. 2024

JMMP

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Copper-based materials have long been used for their outstanding thermal and electrical conductivities in various applications, such as heat exchangers, induction heat coils, cooling channels, radiators, and electronic connectors. The development of advanced copper alloys has broadened their utilization to include structural applications in harsh service conditions found in industries like oil and gas, marine, power plants, and water treatment, where good corrosion resistance and a combination of high strength, wear, and fatigue tolerance are critical. These advanced multi-component structures often have complex designs and intricate geometries, requiring extensive metallurgical processing routes and the joining of the individual components into a final structure. Additive manufacturing (AM) has revolutionized the way complex structures are designed and manufactured. It has reduced the processing steps, assemblies, and tooling while also eliminating the need for joining processes. However, the high thermal conductivity of copper and its high reflectivity to near-infrared radiation present challenges in the production of copper alloys using fusion-based AM processes, especially with Yb-fiber laser-based techniques. To overcome these difficulties, various solutions have been proposed, such as the use of high-power, low-wavelength laser sources, preheating the build chamber, employing low thermal conductivity building platforms, and adding alloying elements or composite particles to the feedstock material. This article systematically reviews different aspects of AM processing of common industrial copper alloys and composites, including copper-chrome, copper-nickel, tin-bronze, nickel-aluminum bronze, copper-carbon composites, copper-ceramic composites, and copper-metal composites. It focuses on the state-of-the-art AM techniques employed for processing different copper-based materials and the associated technological and metallurgical challenges, optimized processing variables, the impact of post-printing heat treatments, the resulting microstructural features, physical properties, mechanical performance, and corrosion response of the AM-fabricated parts. Where applicable, a comprehensive comparison of the results with those of their conventionally fabricated counterparts is provided.

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Section: Microstructure Of Waam-produced Nab Alloysmentioning

confidence: 81%

Section: Microstructure Of Waam-produced Nab Alloysmentioning

confidence: 99%

Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review

Vahedi Nemani,

Ghaffari,

Sabet Bokati

et al. 2024

JMMP

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show abstract

“…Indeed, it is typically observed that, for such WAAM materials, there is little to no anisotropy at the macroscopic scale. [26][27][28] The Young modulus E, the yield stress σ y , the ultimate tensile stress σ UTS and the deformation to failure A % are given in Table 1. For further details on the properties of the machined WAAM bronze-aluminum, refer to Bercelli et al 29 The rough surface of samples extracted from the blocks was analyzed using a Keyence VHX 5000 optical microscope.…”

Section: As-fabricated Waam Surfacementioning

confidence: 99%

“…Tests were performed only in the building direction. Indeed, it is typically observed that, for such WAAM materials, there is little to no anisotropy at the macroscopic scale 26–28 . The Young modulus

E

, the yield stress

σ_{y}

, the ultimate tensile stress

σ_{U T S}

and the deformation to failure

A_{%}

are given in Table 1.…”

Section: Materials and Experimental Set‐upmentioning

confidence: 99%

Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as‐built surfaces

Bercelli

Doudard

Calloch

et al. 2022

Fatigue Fract Eng Mat Struct

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Metal Additive Manufacturing (AM) allows for the fabrication of complex shapes with high added value at low costs. Indeed, as‐built structures are near net shape: they require few to no finishing operations. However, as‐built AM parts present significant roughness caused by the layer discretization. In the case of the Wire and Arc Additive Manufacturing (WAAM) process, used for large‐scale structures, the as‐built roughness is estimated to several hundreds of micrometers. For complex geometries, a complete machining of the surfaces is not necessarily possible. In this study, an experimental method is proposed, relying on thermoelastic stress analysis, to characterize the effect of as‐built WAAM surface roughness on high‐cycle fatigue properties. Using an infrared camera, multiple cracks can be detected and monitored over a large surface on rough WAAM samples under cyclic bending. The collected data constitutes valuable information for the identification of a fatigue model dedicated to as‐built WAAM structures.

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“…Flat samples (Figure 2b) were extracted from a block along its building direction. The transversal direction was not considered, as it was observed in different WAAM materials that there is little to no mechanical anisotropy at the macroscopic scale [5,51,52]. The tests were performed on an MTS tension-torsion servo-hydraulic test rig with a capacity of 250kN.…”

Section: Mechanical Propertiesmentioning

confidence: 99%

A probabilistic approach for high cycle fatigue of Wire and Arc Additive Manufactured parts taking into account process-induced pores

Bercelli

Moyne

D’Hondt

et al. 2021

Additive Manufacturing

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Wire and Arc Additive Manufacturing (WAAM) is a direct-energy deposition technique (unlike SLM or EBM) that builds up a part in a layer-by-layer fashion, each layer being constituted of interlaced weld beads. It is the best suited Additive Manufacturing (AM) technique for large structures thanks to its high deposition rate (5kg/h). The resulting material shows a rough surface, strong residual stress induced by its complex thermal history, a heterogeneous microstructure marked by the different weld passes as well as defects formed by gas pockets. Despite their rarity, pores are found to have a first-order influence on the fatigue life of machined specimens. The discrepancy in their size (> 100µm) and position is responsible for a considerable scatter that makes classical fatigue tests ineffective. The aim of this study is to propose a novel approach to take into account the effect of rare WAAM-induced defects in high cycle fatigue. To achieve this, numerical porous structures are generated from the knowledge of the real pore population determined by tomography. Their fatigue performances are predicted via a two-scale probabilistic model identified on experimental self-heating results, on which pores have no influence. In that sense, the probabilistic model describes the behaviour of a virtually healthy material. Then, by computing a database of representative pore cases, the whole bundle of Wöhler curves for each numerical porous structure is determined. Finally, the numerical fatigue scatter is in close agreement with experimental data, and it is shown that the ranking in pore criticality according to the model matches the fractography observations. Keywords: Wire and Arc Additive Manufacturing (WAAM) ; High cycle fatigue ; Pores ; Self-heating ; Poisson point process Draft articleIRDL fatigue life of the position of an isolated pore over its size. From this observation a novel approach is proposed in [16], where the total plastic zone in the vicinity of a defect is considered from Finite Element Analysis (FEA). Although gas pores found in WAAM parts have much larger dimensions (>100µm) and have smooth near-spherical shapes [23][24][25], to which notch fatigue and crack initiation approaches are best suited [26,27].In the case of WAAM, a low density of defects can be achieved using the Cold Metal Transfer (CMT) technology [28,29]. Typical WAAM defects are round smooth pores, with sizes ranging from a few micrometers to more than half a millimeter [23,30]. Fatigue samples extracted from optmized WAAM blocks show rare isolated pores with an important discrepancy in size and distance to free surface. As a result, a considerable scatter in fatigue data is observed [31] (for example compared to casting materials), posing quite a challenge to the assessment of fatigue properties by conventional methods (ASTM E466-15 standard [32], the staircase method [33]). These samples do not constitute a Representative Volume Element (RVE) of the material's fatigue behaviour: each sample can be seen as a unique structure. This is t...

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Evaluation of tandem controlled short-circuit GMAW for improved deposition in additive manufacture of large Nickel Aluminium Bronze naval components

Cited by 13 publications

References 4 publications

Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review

Advancements in Additive Manufacturing for Copper-Based Alloys and Composites: A Comprehensive Review

Thermometric investigations for the characterization of fatigue crack initiation and propagation in Wire and Arc Additively Manufactured parts with as‐built surfaces

A probabilistic approach for high cycle fatigue of Wire and Arc Additive Manufactured parts taking into account process-induced pores

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