Heat distribution in welds of a 6061-T6 aluminum alloy obtained by modified indirect electric arc

Gómora, César Mendoza; Ambriz, R.R.; Curiel, F.F.; Jaramillo, David

doi:10.1016/j.jmatprotec.2017.01.003

Cited by 12 publications

(5 citation statements)

References 11 publications

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“…A further reduction in the welding current led to the construction of a 3.4 mm thin wall, which had poor remelting characteristics. With the excessive reduction in the welding current, the energy input per unit length is too small for the base material to melt and adhere to the deposited base layer [ 43 ] (i.e., sample A4 in Figure 9 ). The droplets in this case consist of hardened (solidified) filler material, which makes it unfeasible to build further layers on top as the mechanical integrity of the first deposit is poor [ 44 ].…”

Section: Analysis Of Arc Deposition Parameters (Planning Phase)mentioning

confidence: 99%

“…The welding program (in the CMT-WAAM system) allowed for the adjustment of parameters such as the ignition current for welding, the ignition/final current extent (duration), the current at the end of welding, and the interval between the transitions [ 43 , 45 ]. The parameters were adjusted so that the material at the beginning and at the end was not excessively melted.…”

Section: Analysis Of Arc Deposition Parameters (Planning Phase)mentioning

confidence: 99%

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Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

et al. 2022

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Additive technologies enable the flexible production through scalable layer-by-layer fabrication of simple to intricate geometries. The existing 3D-printing technologies that use powders are often slow with controlling parameters that are difficult to optimize, restricted product sizes, and are relatively expensive (in terms of feedstock and processing). This paper presents the development of an alternative approach consisting of a CAD/CAM + combined wire arc additive-manufacturing (WAAM) hybrid process utilizing the robotic MIG-based weld surfacing and milling of the AlSi5 aluminum alloy, which achieves sustainably high productivity via structural alloys. The feasibility of this hybrid approach was analyzed on a representative turbine blade piece. SprutCAM suite was utilized to identify the hybrid-manufacturing parameters and virtually simulate the processes. This research provides comprehensive experimental data on the optimization of cold metal transfer (CMT)–WAAM parameters such as the welding speed, current/voltage, wire feed rate, wall thickness, torch inclination angle (shift/tilt comparison), and deposit height. The multi-axes tool orientation and robotic milling strategies, i.e., (a) the side surface from rotational one-way bottom-up and (b) the top surface in a rectangular orientation, were tested in virtual CAM environments and then adopted during the prototype fabrication to minimize the total fabrication time. The effect of several machining parameters and robotic stiffness (during WAAM + milling) were also investigated. The mean deviation for the test piece’s tolerance between the virtual processing and experimental fabrication was −0.76 mm (approx.) at a standard deviation of 0.22 mm assessed by 3D scanning. The surface roughness definition Sa in the final WAAM pass corresponds to 36 µm, which was lowered to 14.3 µm after milling, thus demonstrating a 55% improvement through the robotic comminution. The tensile testing at 0° and 90° orientations reported fracture strengths of 159 and 161.3 MPa, respectively, while the yield stress and reduced longitudinal (0°) elongations implied marginally better toughness along the WAAM deposition axes. The process sustainability factors of hybrid production were compared with Selective Laser Melting (SLM) in terms of the part size freedom, processing costs, and fabrication time with respect to tight design tolerances. The results deduced that this alternative hybrid-processing approach enables an economically viable, resource/energy feasible, and time-efficient method for the production of complex parts in contrast to the conventional additive technologies, i.e., SLM.

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Section: Analysis Of Arc Deposition Parameters (Planning Phase)mentioning

confidence: 99%

Section: Analysis Of Arc Deposition Parameters (Planning Phase)mentioning

confidence: 99%

Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

et al. 2022

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“…Ineptly, the temperature usually ranges during welding which is quite enough to reverse the effect of heat treatment (T6) and directional rolling which dispense the material strength just above annealed (O) state [4]. It is evident from the literature for AA6061-T6 that a straight reduction of 45% in yield strength [5], 40% in tensile strength [4,9], 43-45% of hardness [5,10] was frequently observed against the arc welding processes. Still and all, limited attempts are reported in the literature for controlling the weldment properties which broadly includes: inoculation created with nucleates, magnetic arc oscillation [11,12], pulsed current utilization, gas impingement from the surface, vibration inducement from exciting source [13] and cold metal transfer (CMT) techniques.…”

Section: Page 2 Of 13mentioning

confidence: 99%

Modified utilization of semi-sectioned tubes as filler coated with MWCNTs–TiO2 in TIG arc welding to recover fusion lost mechanical properties of the weldment

Muzamil

Samiuddin

2018

J Braz. Soc. Mech. Sci. Eng.

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The loss of mechanical properties in heat treatable aluminum alloys categories during arc fusion welding processes is a critical issue, which limits the direct application in contrast to different post-treatments methods. This work involved a strategy for the novel and distinctive formation of fillers using 3-mm-diameter (AA6061) tubes having MWCNTs and TiO 2 nanoparticles coating on the inner surface. A series of experiments were conducted using TIG welding to evaluate the effect of welding current and composition of inside coating (MWCNTs-TiO 2) contents on welding strength. Three gradually increasing current values (160 A, 180 A and 200 A) were selected and tested against three combinations of nanocomposite coatings that include 1 wt% MWCNTs-TiO 2 , 1.5 wt% MWCNTs-TiO 2 and 2 wt% MWCNTs-TiO 2. Acceptable qualified bonding between nanocomposite and inside surface is utmost important before conducting the experiments, Tape Test (ASTM-D3359-09 e2) was performed for the assessment of bonding conditions and led to qualitatively exceptional bonding conditions after applying vacuum heating cycle. Tensile test results have demonstrated a significant improvement of 34.20-45.65% strength using innovative nanocomposite coated semi-sectioned tube in comparison to tube fillers without coating. Meanwhile, a beneficial gradually forming W-shape microhardness profile in contrast to conventional U and V shape profiles was achieved at 1.5 and 2 wt% of MWCNTs, and the uplift of hardness in the WZ region up to 86.51% subjected to increase high MWCNTs contents in combination with the current. Therefore, it is concluded to be a virtuous strategy for reinforcing mechanism of weldments to encounter some fusion property loss in aluminum alloys.

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“…Walter et al [14] attributed the variation in hardness across the HAZ and in the tensile properties in different welding processes to microstructural variations. Gómora et al [17] reported observing a low hardness subzone within the HAZ, with optical microscopy indicating no apparent significant grain size changes in this subzone.…”

Section: Introductionmentioning

confidence: 98%

Microstructure and Thermal Mechanical Behavior of Arc-Welded Aluminum Alloy 6061-T6

Arhumah,

Pham

2024

JMMP

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In this study, the welding thermal cycle, as well as the microstructural and mechanical properties of welded AA6061-T6 plates, were studied. The plates were prepared and bead-on-plate welded using gas metal arc welding (GMAW). Numerical simulations using SYSWELD® were performed to obtain the thermal distribution in the welded plates. The numerical heat source was calibrated using the temperatures obtained from the experimental work and the geometry of the melting pool. The mechanical properties were obtained through microhardness tests and were correlated with the welding thermal cycle. Moreover, the mechanical behavior and local deformation in the heat-affected zone (HAZ) were investigated using micro-flat tensile (MFT) tests with digital image correlation (DIC). The mechanical properties of the subzones in the HAZ were then correlated with the welding thermal cycle and with the microstructure of the HAZ. It was observed that the welding thermal cycle produced microstructural variations across the HAZ, which significantly affected the mechanical behavior of the HAZ subzones. The results revealed that MFT tests with the DIC technique are an excellent tool for studying the local mechanical behavior change in AA6061-T6 welded parts due to the welding heat.

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Heat distribution in welds of a 6061-T6 aluminum alloy obtained by modified indirect electric arc

Cited by 12 publications

References 11 publications

Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

Sustainable Hybrid Manufacturing of AlSi5 Alloy Turbine Blade Prototype by Robotic Direct Energy Layered Deposition and Subsequent Milling: An Alternative to Selective Laser Melting?

Modified utilization of semi-sectioned tubes as filler coated with MWCNTs–TiO2 in TIG arc welding to recover fusion lost mechanical properties of the weldment

Microstructure and Thermal Mechanical Behavior of Arc-Welded Aluminum Alloy 6061-T6

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