Forming characteristics and control method of weld bead for GMAW on curved surface

Ni, Mao; Qin, Xunpeng; Hu, Zeqi; Ji, Feilong; Yang, Shiming; Wang, Shuxin

doi:10.1007/s00170-021-08191-z

Cited by 9 publications

(4 citation statements)

References 28 publications

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“…A control cabinet was used to coordinate the robot and the welding power supply. A mixture of shielding gas (18% CO 2 and 82% Ar) was used to improve the arc and droplet transfer stability during the welding process [ 32 ].…”

Section: Methodsmentioning

confidence: 99%

Microstructure and Mechanical Properties of Gradient Interfaces in Wire Arc Additive Remanufacturing of Hot Forging Die Steel

Qin

et al. 2023

Materials

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Hot forging dies are subjected to periodic thermal stress and often fail in the forms of thermal fatigue, wear, plastic deformation, and fracture. A gradient multi-material wire arc additive remanufacturing method for hot forging dies was proposed to extend the service life of hot forging dies and reduce total production costs. The properties of multi-material gradient interfaces play a critical role in determining the overall performance of the final products. In this study, the remanufacturing zone of a hot forging die was divided into three deposition layers: the transition layer, the intermediate layer, and the strengthening layer. Experiments of wire arc additive manufacturing with gradient material were conducted on a 5CrNiMo hot forging die steel. The microstructure, microhardness, bonding strength, and impact property of gradient interfaces were characterized and analyzed. The results revealed that the gradient additive layers and their interfaces were defect-free and that the gradient interfaces had obtained a high-strength metallurgical bonding. The microstructure of the gradient additive layers presented a gradient transformation process of bainite-to-martensite from the bottom to the top layer. The microhardness gradually increased from the substrate layer to the surface-strengthening layer, forming a three-level gradient in the range of 100 HV. The impact toughness values of the three interfaces were 46.15 J/cm2, 54.96 J/cm2, and 22.53 J/cm2, and the impact fracture morphology ranged from ductile fracture to quasi-cleavage fracture. The mechanical properties of the gradient interfaces showed a gradient increase in hardness and strength, and a gradient decrease in toughness. The practical application of hot forging die remanufactured by the proposed method had an increase of 37.5% in average lifespan, which provided scientific support for the engineering application of the gradient multi-material wire arc additive remanufacturing of hot forging dies.

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Section: Methodsmentioning

confidence: 99%

Microstructure and Mechanical Properties of Gradient Interfaces in Wire Arc Additive Remanufacturing of Hot Forging Die Steel

Qin

et al. 2023

Materials

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“…Furthermore, based on the literature survey [121][122][123][124][125][126][127][128][129][130][131][132][133][134][135][136], it becomes clear that the LSP deformation zone penetration (measuring 0.7 ± 0.20 mm) is adequate to achieve grain size refinement in laser-and electron beam-based DED as well as PBF. However, its impact is significantly limited in arc plasma-based DED due to the extensive deposition penetration [137][138][139] since the previously deposited layer is almost entirely remelted. It is worth noting that, to the best of the authors' knowledge, the in situ interlayer LSP was not applied to DED-arc components; only Sun et al [121] applied the LSP (post-deposition) to the side surface of 2319 aluminum DEDed-arc walls.…”

Section: Laser Shock Peeningmentioning

confidence: 99%

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

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Directed energy deposition (DED) additive manufacturing systems have been developed and optimized for typical engineering materials and operational requirements. However, parts fabricated via DED often demonstrate a diminished material response, encompassing inferior mechanical properties and heat treatment outcomes compared to traditionally manufactured components (e.g., wrought and cast materials). As a result, parts produced by DED fail to meet stringent specifications and industry requirements, such as those in the nuclear, oil and gas, and aeronautics sectors, potentially limiting the industrial scalability of DED processes. To address these challenges, systems integrating DED with interlayer (cold or hot) mechanical deformation (e.g., rolling and hammering/peening, forging) have been developed. These systems refine the microstructure, mitigate the typical crystallographic texture through static and/or dynamic recrystallization, and enhance mechanical properties and heat treatment responses without altering material specifications. In this regard, the present state-of-the-art review reports the DED + interlayer mechanical deformation systems and their variants, and their potential and limitations, providing a critical analysis to support the development and adaptation of this technology to overcome the process and material limitations that currently prevent the large-scale industrial adoption of DED processes. Furthermore, a detailed description of the grain size refinement mechanisms induced by interlayer mechanical deformation and their respective effects on the mechanical properties of commonly used 3D-printed engineering alloys (e.g., Ti-6Al-4V, Inconel 718, various low-alloy steels, AISI 316L stainless steel, and Al-based series 2xxx) is comprehensively analyzed.

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“…Nguyen et al [ 3 ] confirmed that the powerful momentum of the reverse flow of molten metal in the molten pool was the main factor causing the hump by collecting sequential images during the hump formation. With the maturity of hump research, many scholars simulated hump welding by numerical calculations [ 4 , 5 , 6 , 7 , 8 ], calculated the velocity distribution of liquid metal in the molten pool, observed the flow state of molten pool more intuitively, and verified the effect of reverse metal flow on hump formation. If the characteristics of the reverse metal flow are directly extracted by experimental method, the relationship between the liquid metal flow and welding parameters and forming can be quantitatively analyzed.…”

Section: Introductionmentioning

confidence: 99%

Effect of Mechanical Stirring on High-Speed GMAW Hump Bead

et al. 2023

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High-speed GMAW tends to be accompanied by periodic humping defects, thereby reducing the weld bead quality. A new method was proposed to actively control the weld pool flow for eliminating humping defects. A high-melting point solid pin was designed and inserted into the weld pool to stir the liquid metal during the welding process. The characteristics of the backward molten metal flow were extracted and compared by a high-speed camera. Combined with particle tracing technology, the momentum of the backward metal flow was calculated and analyzed, and the mechanism of hump suppression in high speed GMAW was further revealed. The stirring pin interacted with the liquid molten pool, resulting in a vortex zone behind the stirring pin, which significantly reduced the momentum of the backward molten metal flow, and thus it inhibited the formation of humping beads.

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Forming characteristics and control method of weld bead for GMAW on curved surface

Cited by 9 publications

References 28 publications

Microstructure and Mechanical Properties of Gradient Interfaces in Wire Arc Additive Remanufacturing of Hot Forging Die Steel

Microstructure and Mechanical Properties of Gradient Interfaces in Wire Arc Additive Remanufacturing of Hot Forging Die Steel

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Effect of Mechanical Stirring on High-Speed GMAW Hump Bead

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