Fabrication, characterisation, and finite element analysis of cold metal transfer–based wire and arc additive–manufactured aluminium alloy 4043 cylinder

Pramod, R.; Kumar, S. Mohan; Girinath, B.; Kannan, A. Rajesh; Kumar, N. Pravin; Shanmugam, N. Siva

doi:10.1007/s40194-020-00970-8

Cited by 25 publications

(18 citation statements)

References 34 publications

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“…The heat accumulation and low solidification rate would result in a coarser microstructure. The same findings were obtained from Pramod et al [45]. According to the author, the first deposited layer at the base of the cylinder had a fine microstructure, indicating a greater solidification rate, and heat dissipation was increased owing to the existence of the substrate.…”

Section: Microstructure Analysissupporting

confidence: 82%

“…Hao et al [44] also found that columnar grains expanded around the fusing line and converted into equiaxed grains towards the top of the build-up wall, decreasing grain size as travel speed increased. Arc length correction (ALC) was also important in bead geometry development [45]. Kannan et al [46] found that ALC greater than zero resulted in less dilution and higher bead height, whereas ALC less than zero resulted in more dilution and lower bead height.…”

Section: Performance Evaluation Of Waam Of Er4043mentioning

confidence: 99%

“…Kindermann et al [50] claimed that a high deposition rate, along with increased heat input and solidification time, worsened the porosity in aluminium as more hydrogen was absorbed into the weld pool. Furthermore, Pramod et al [45] mentioned that majority of the pores observed at the top layers were caused by undissolved hydrogen due to a discrepancy in solubility between the liquid and solid phases. Ortega et al [18] concurred with the observation.…”

Section: Microstructure Analysismentioning

confidence: 99%

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2023

JMechE

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All published articles in this journal are open accessed. This allows anybody to freely download, print, copy, distribute or read them, as well as to reused and quoted with proper credit to the original published version. By submitting an article to JMechE, the authors grant full right to the journal to publish the article online once it has been accepted. However, the authors held ownership of their article.

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Section: Microstructure Analysissupporting

confidence: 82%

Section: Performance Evaluation Of Waam Of Er4043mentioning

confidence: 99%

Section: Microstructure Analysismentioning

confidence: 99%

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2023

JMechE

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“…The variation patterns of the thermal cycle temperature in this research are in accordance with results that have been proved to be valid. [43][44][45] In addition, it is a good way to use the measured temperature of the molten pool to test the thermal simulation result. However, there are difficulties in accurately measuring the temperature of the molten pool in the molten state during the deposition process.…”

Section: Grid Configuration and Materials Propertiesmentioning

confidence: 99%

Effects of Heat Input on Morphology of Thin‐Wall Components Fabricated by Wire and Arc Additive Manufacturing

et al. 2021

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In the process of wire and arc additive manufacturing (WAAM), it is crucial to improve the surface quality and maintain a uniform building morphology. Unacceptable morphology of components influences the surface roughness and deposition efficiency, limiting the application of WAAM in the fabrication of complex‐shaped components. Herein, linear energy density is used to estimate the applied heat input. The single‐pass single‐layer bead morphology is analyzed to establish the relationship between linear energy density and the bead width ratio to bead height. In addition, four four‐layer components under different heat inputs are deposited to reveal the process of multilayer deposition. According to the morphology and surface appearance, heat input effects on surface roughness, straightness, and deposition efficiency are investigated. Then, a relationship is established to predict the outcomes of heat input on deposition quality. It is inferred that good deposition performance can be obtained when the linear energy density lies around 600 J mm−1. A simulation based on the Simufact welding software is made on temperature field distribution and thermal cycles to illustrate the relationship, confirmed by 3D scanning results. At last, based on the investigations, a uniform and well‐formed thin‐wall component is fabricated, and its deposition efficiency can reach 80%.

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“…They showed the effect of solidification parameters on the microstructure with the rapid prediction of the solidification in the laser powder fusion process, where the predicted temperature and microstructure profiles of the deposited tracks were found to be in a good agreement with their experimental observations. Pramod et al 9 used the finite element method (FEM), that was conducted using Abaqus welding interface plug-in, to predict the stress, strain, and temperature distributions at various stages of additive layer depositions. They recorded tensile strength and elongation percentage for 0 , 45 , and 90 orientations and enhanced properties were observed when compared with wrought counter parts.…”

Section: Introductionmentioning

confidence: 99%

Experimental and computational analysis of additively manufactured tensile specimens: Assessment of localized-cooling rate and ductile fracture using the Gurson– Tvergaard–Needleman damage model

Darabi

Azinpour

Fiorentin

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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The present contribution addresses the micromechanical and thermal analysis of directed energy deposition-manufactured, stainless steel 316L components by utilizing experimental and numerical analyses. It has been established that a combination of controlling process parameters, manufacturing environment and microstructural anisotropies could adversely affect the quality of as-deposited parts. Among other factors, the shape, size, and distribution of the microvoids and porosities could, to some extent, have deteriorating effects on the mechanical properties of the additively manufactured components. In this work, the micromechanically motivated Gurson–Tvergaard–Needleman damage model is utilized and the performance of the model is evaluated by observing the damage accumulation in the loaded additively manufactured specimens. By relying to the laboratory-based material data and fractographic imagery from nonstandard tensile testing on fabricated samples in different building directions, numerical model predictions are found to be in a good agreement with the experimental observations. Furthermore, by resorting to the finite element software capabilities, the thermal analyses are carried out on the manufactured cube component and the influence of the process parameters on the temperature distribution is revealed.

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Fabrication, characterisation, and finite element analysis of cold metal transfer–based wire and arc additive–manufactured aluminium alloy 4043 cylinder

Cited by 25 publications

References 34 publications

Untitled

Untitled

Effects of Heat Input on Morphology of Thin‐Wall Components Fabricated by Wire and Arc Additive Manufacturing

Experimental and computational analysis of additively manufactured tensile specimens: Assessment of localized-cooling rate and ductile fracture using the Gurson– Tvergaard–Needleman damage model

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