Finite Element Modelling of Wire-arc-additive-manufacturing Process

Montevecchi, Filippo; Venturini, Giuseppe; Scippa, Antonio; Campatelli, Gianni

doi:10.1016/j.procir.2016.08.024

Cited by 114 publications

(63 citation statements)

References 17 publications

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“…In the numerical model, the double-ellipsoidal heat source according to Goldak [22] was considered. This is a typical approach for common arc-welding simulations, and replicates the thermal energy input well [13,14,19,22]. The underlying energy density function subdivides the weld pool along the welding path (z-axis) into the front (cf) and rear areas (cr), and is primarily dominated by the welding power [22].…”

Section: Boundary Conditionsmentioning

confidence: 93%

“…Some numerical studies consider each welding seam as rectangular cross-sections [11,12,19]. In the present investigation, a realistic simplified semi-circular cross section was modelled in MSC Marc for the first layers, followed by a sickle-shape for the subsequent layers, each shifted by the resulting offset relative to the previous position.…”

Section: Boundary Conditionsmentioning

confidence: 99%

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Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Graf

Hälsig

Höfer

et al. 2018

Metals

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Additive manufacturing processes have been investigated for some years, and are commonly used industrially in the field of plastics for small- and medium-sized series. The use of metallic deposition material has been intensively studied on the laboratory scale, but the numerical prediction is not yet state of the art. This paper examines numerical approaches for predicting temperature fields, distortions, and mechanical properties using the Finite Element (FE) software MSC Marc. For process mapping, the filler materials G4Si1 (1.5130) for steel, and AZ31 for magnesium, were first characterized in terms of thermo-physical and thermo-mechanical properties with process-relevant cast microstructure. These material parameters are necessary for a detailed thermo-mechanical coupled Finite Element Method (FEM). The focus of the investigations was on the numerical analysis of the influence of the wire feed (2.5–5.0 m/min) and the weld path orientation (unidirectional or continuous) on the temperature evolution for multi-layered walls of miscellaneous materials. For the calibration of the numerical model, the real welding experiments were carried out using the gas-metal arc-welding process—cold metal transfer (CMT) technology. A uniform wall geometry can be produced with a continuous welding path, because a more homogeneous temperature distribution results.

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Section: Boundary Conditionsmentioning

confidence: 93%

Section: Boundary Conditionsmentioning

confidence: 99%

Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Graf

Hälsig

Höfer

et al. 2018

Metals

View full text Add to dashboard Cite

show abstract

“…The moving welding heat source was approximated by a double ellipsoidal power density distribution developed by Goldak et al [131]. Montevecchi et al [132] split the heat source into two power distribution contributions: one that characterizes the power delivered to the base material adapted from the double ellipsoid Goldak model and another constant of power distribution that should be developed to describe the energy transferred to the wire, since only 50% of the total energy was used to melt the wire [133].…”

Section: Modeling and Simulation For Waammentioning

confidence: 99%

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

et al. 2019

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Additive manufacturing has revolutionized the manufacturing paradigm in recent years due to the possibility of creating complex shaped three-dimensional parts which can be difficult or impossible to obtain by conventional manufacturing processes. Among the different additive manufacturing techniques, wire and arc additive manufacturing (WAAM) is suitable to produce large metallic parts owing to the high deposition rates achieved, which are significantly larger than powder-bed techniques, for example. The interest in WAAM is steadily increasing, and consequently, significant research efforts are underway. This review paper aims to provide an overview of the most significant achievements in WAAM, highlighting process developments and variants to control the microstructure, mechanical properties, and defect generation in the as-built parts; the most relevant engineering materials used; the main deposition strategies adopted to minimize residual stresses and the effect of post-processing heat treatments to improve the mechanical properties of the parts. An important aspect that still hinders this technology is certification and nondestructive testing of the parts, and this is discussed. Finally, a general perspective of future advancements is presented.

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“…Xiong et al [4,5] studied the thermal behavior of cylindrical parts made by WAAM through a finite element thermal simulation of the process. Montevecchi et al [6,7] developed a finite element model based on a mesh coarsening technique in order to reduce the computational cost of the process simulation. In the same perspective, Ding et al [10] proposed a finite element approach based on two models (transient and stationary) in order to investigate the thermomechanical behavior of parts manufactured in WAAM.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

Chergui

Béraud

Vignat

et al. 2021

Lecture Notes in Mechanical Engineering

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Wire arc additive manufacturing allows the production of metallic parts by depositing beads of weld metal using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this work, a new finite element technique is proposed in order to model metal deposition in WAAM process. This technique allows to gradually construct the mesh representing the deposited regions along the deposition path. The heat source model proposed by Goldak is adapted and combined with the proposed metal deposition technique taking into account the energy distribution between filler material and the molten pool. The effectiveness of the proposed method is validated by series of experiments, of which an example is detailed in this paper.

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Finite Element Modelling of Wire-arc-additive-manufacturing Process

Cited by 114 publications

References 17 publications

Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

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