Heat accumulation prevention in Wire-Arc-Additive-Manufacturing using air jet impingement

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

doi:10.1016/j.mfglet.2018.06.004

Cited by 68 publications

(29 citation statements)

References 20 publications

(22 reference statements)

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“…The average hardness of 179 HV, 196 HV and 232 HV (reference, aerosol, water bath) was obtained, while the maximal hardness difference between the cooling regimes was up to 120 HV (140-260 HV). Montevecchi et al [15] proposed a cooling system where a coolant hose is attached to the welding nozzle and conveys the air jet on the deposited surface a few layers below the point of the deposition. The effectiveness of their method was assessed using a finite element thermal model of the WAAM of structural steel walls.…”

Section: Introductionmentioning

confidence: 99%

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Kozamernik

Bračun

Klobčar

2020

Int J Adv Manuf Technol

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In an attempt to find a solution similar to the FDM 3D printers which would allow cost-effective and reliable additive manufacturing of metal components, this paper proposes a three-axis WAAM system capable of reliably printing small, near-net-shape metal objects. The system consists of gas metal arc (GMA) process equipment, a three-axis CNC positioning system, the interpass temperature control and forced cooling of the base plate and the deposit. The main challenge addressed is the minimisation of shape distortions caused by excessive heat accumulation when printing small objects. The interpass temperature control uses an IR pyrometer to remotely measure the last deposited layer and a control system to keep the interpass temperature below the predefined value by stopping the deposition after each layer in order to allow the deposit to cool. This results in a stable and more repeatable shape of the deposit, even when the heat transfer conditions are changing during the build-up process. The combination of adaptive interlayer dwell time and forced cooling significantly improves system productivity. Open-source NC control and path generation software is used, which enables fast and easy creation of the control code. Different control methods are evaluated through the printing of simple walls, and the printing accuracy is evaluated by printing small shell objects. As the results show, the interpass temperature control allows small objects to be printed at near-net shape with a deviation of 2%, which means that successful printing of 3D shapes can be achieved without trial and error approach.

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Section: Introductionmentioning

confidence: 99%

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Kozamernik

Bračun

Klobčar

2020

Int J Adv Manuf Technol

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“…[ 18 ] While the bypass gas not only protects the surface of the additive metal but also accelerates the cooling of the metal side part of the block. [ 23 ] The crystallization angle was shifted in the direction perpendicular to the molten pool surface, and the crystal was crystallized along the direction with the maximum temperature gradient of 70°.…”

Section: Discussionmentioning

confidence: 99%

“…[ 21 ] The AM with arc as a heat source has the advantages of high deposition rate, low equipment cost, and suitable for large‐scale components. [ 22–25 ] Nowadays, various AM techniques have been applied to the production of Inconel 625 alloy parts, [ 7 ] such as selective laser melting (SLM), directed energy deposition (DED), laser metal fusion (LMF), electron beam melting (EBM), and wire arc additive manufacture (WAAM). However, both of these processes adopt laser beams and electron beams as the heat sources are limited in processing efficiency and production of large parts.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Thick‐Walled Inconel 625 Alloy Manufactured by Wire Arc Additive Manufacture with Different Torch Paths

Jiang

Zhang

et al. 2020

Adv Eng Mater

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Wire arc additive manufacture (WAAM) technology has attracted more and more attention. WAAM technology provides a way to manufacture a large‐scale part at a low cost and with less material loss. Inconel 625 alloys are widely used for their excellent mechanical properties and corrosion resistance. Therefore, it is important to investigate the performance of Inconel 625 alloy in WAAM. Herein, cold metal transfer (CMT) arc is used as the heat source to fabricate thick‐walled parts of Inconel 625 alloy by WAAM, and study the difference between microstructure and mechanical properties under the different torch trajectories. The result shows that the grains inside the parts are all thick dendrites and show the trend of epitaxial growth. The thermal input of the oscillation additive is higher than the two‐pass multilayer additives, and the Laves phase also precipitated more. The maximum tensile strength occurs in parallel sampling close to the substrate, which is 693.5 ± 12.6 and 751.2 ± 17.6 MPa in oscillation and two‐pass multilayer modes, respectively. The maximum elongation is obtained in the vertical direction is 60 ± 1.0% and 60 ± 1.1%. The anisotropies are 4% and 4.5%, respectively. The maximum hardness value under the two torch trajectories also appears close to the substrate.

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“…They used small parts of Fe alloys in their study. Their results showed that the impinging air jet can prevent the heat accumulation on part produced by WAAM [14]. Bintao et al used in-situ temperature measurement method to analyze the heat accumulation and thermal behavior in Gas Tungsten Wire Arc Additive Manufacturing (GT-WAAM) process.…”

Section: Literature Reviewmentioning

confidence: 99%

“…This issue happens when the average temperature of the workpiece increases continuously. That will cause many other defects, such variation in mechanical properties and microstructure evolution, and variation in grain size which will, consequently, lead to undesirable part quality, such structural collapse [14]. This issue is also mostly inherent to DED category of the MAM.…”

Section: Heat Accumulationmentioning

confidence: 99%

An Investigation of the Metal Additive Manufacturing Issues and Perspective for Solutions Approach

Al-Shebeeb¹

2021

Concepts, Applications and Emerging Opportunities in Industrial Engineering

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Metal Additive Manufacturing (MAM) is delivering a new revolution in producing three-dimensional parts from metal-based material. MAM can fabricate metallic parts with complex geometry. However, this type of Additive Manufacturing (AM) is also impacted by several issues, challenges, and defects, which influence product quality and process sustainability. In this chapter, a review has been made on the types of small to medium-sized metallic parts currently manufactured using the MAM method. Then, investigation was undertaken to analyze the defects, challenges, and issues inherent to the design for additive manufacturing, by using MAM method. MAM-related obstacles are discussed in depth in this chapter and these obstacles occur in all size of metal printed parts. The reasons and solutions presented by previous researchers of these obstacles are discussed as well. A potential approach based on the author's knowledge and analysis for solving these issues and challenges is suggested in this chapter. Based on the author's conclusion, the MAM is not limited by part size, material, or geometry. In order to validate the potential solutions developed by the author of this work, performing actual MAM process is required and a local visit to manufacturing factories are also important to visualize these challenges and issues.

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Heat accumulation prevention in Wire-Arc-Additive-Manufacturing using air jet impingement

Cited by 68 publications

References 20 publications

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Microstructure and Mechanical Properties of Thick‐Walled Inconel 625 Alloy Manufactured by Wire Arc Additive Manufacture with Different Torch Paths

An Investigation of the Metal Additive Manufacturing Issues and Perspective for Solutions Approach

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