Experimental and simulative investigation of welding sequences on thermally induced distortions in wire arc additive manufacturing

Abstract

Purpose The purpose of this paper is to demonstrate the impact of the welding sequence on the substrate plate distortion during the wire and arc additive manufacturing (WAAM) process. This paper also aims to show the capability of finite element simulations in the prediction of those thermally induced distortions. Design/methodology/approach An experiment was conducted in which solid aluminum blocks were manufactured using two different welding sequences. The distortion of the substrates was measured at predefined positions and converted into bending and torsion values. Subsequently, a weakly coupled thermo-mechanical finite element model was created using the Abaqus simulation software. The model was calibrated and validated with data gathered from the experiments. Findings The results of this paper showed that the welding sequence of a part significantly affects the formation of thermally induced distortions of the final part. The calibrated simulation model was able to capture the different distortion behavior attributed to the welding sequences. Originality/value Within this work, a simulation model was developed capable of predicting the distortion of WAAM parts in advance. The findings of this paper can be used to improve the design of WAAM welding sequences while avoiding high experimental efforts.

Optimizing Melt Pool Temperature Prediction Using Convolutional Bilstm with Insights from Dragonfly Behavior in Wire-Arc Additive Manufacturing

“…They simulated a reactivation region, which reflected the re-melting and annealing of the earlier formed material, to examine "the activation of elements to model the material deposition." Article [13] examined two different welding procedures for a WAAM part with a block shape. Both "an asymmetric welding sequence (WS1) and a symmetric welding sequence (WS2)" were used in the production of the specimens.…”

Simulation of Wire Arc Additive Manufacturing in the Reinforcement of a Half-Cylinder Shell Geometry

“…The simulative approach is mainly based on the model in [ 16 ] and the simulation environment is shown in Figure 5 . A cuboid heat source was used to model the heat input through the electric arc.…”

“…Two linear elements were used to resolve the width and the height of each weld bead. This meshing strategy is based on the mesh convergence study of a previous simulation [ 16 ]. By applying this rule to the deposition geometry, the number of required elements could be calculated.…”

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

“…In this study, methods of examining and measuring RS, the impact of RS on material characteristics of WAAM products, and process parameters based on both experimental and numerical analysis were discussed, while the mitigation of the RS and refining grain structure of created layer parts improved based on the experimental methods was discussed. In this review, the effects of process parameters like wire diameter, scan length with width, height (thickness) of bead, arc current behavior [20], voltage, travel speed, welding sequence (welding position) [21], types of shield gas, and its flow rate on RS are considered. Also, studies on the consequence of interlayer bead surface condition and inter pass time on the deposit shape additively increased height were considered.…”