High deposition wire arc additive manufacturing of mild steel: Strategies and heat input effect on microstructure and mechanical properties

Aldalur, Eider; Veiga, Fernando; Suárez, Alejandro Rosete; Bilbao, Jon; Lamíkiz, Aitzol

doi:10.1016/j.jmapro.2020.08.060

Cited by 106 publications

(28 citation statements)

References 22 publications

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“…Naturally, microstructure changes were observed between the top layer and the remaining layers that underwent thermal retreatment from multiple thermal cycles. This behaviour was also observed by Aldalur et al [20] and Kozamernik et al [21] when using WAAM with the same ER70S-6 wire. To illustrate this behaviour, Fig.…”

Section: Validation Of the Reference Working Envelopesupporting

confidence: 81%

Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM

Teixeira

Scotti

Vilarinho

et al. 2021

Int J Adv Manuf Technol

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This work aims to propose and assess a methodology for parameterization for WAAM of thin walls based on a previously existing working envelope built for a basic material (parameter transferability). This work also aimed at investigating whether the working envelope approach can be used to optimize the parameterization for a target wall width in terms of arc energy (which governs microstructure and microhardness), surface finish and active deposition time. To reach the main objective, first, a reference working envelope was developed through a series of deposited walls with a plain C-Mn steel wire. Wire feed speed (WFS) and travel speed (TS) were treated as independent variables, while the geometric wall features were considered dependent variables. After validation, three combinations of WFS and TS capable of achieving the same effective wall width were deposited with a 2.25Cr-1Mo steel wire. To evaluate the parameter transferability between the two materials, the geometric features of these walls were measured and compared with the predicted values. The results showed minor deviations between the predicted and measured values. As a result, WAAM parameter selection for another material showed to be feasible after only fewer experiments (shorter time and lower resource consumption) from a working envelope previously developed. The usage of the approach to optimize parameterization was also demonstrated. For this case, lower values of WFS and TS were capable of achieving a better surface finish. However, higher WFS and TS are advantageous in terms of production time. As long as the same wall width is maintained, variations in WFS and TS do not significantly affect microstructure and microhardness.

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Section: Validation Of the Reference Working Envelopesupporting

confidence: 81%

Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM

Teixeira

Scotti

Vilarinho

et al. 2021

Int J Adv Manuf Technol

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“…In the central part in every layer limit also can be found acicular ferrite/bainite small areas but the microstructure mainly is composed by polygonal ferrite zones. A more detailed analysis of the microstructure can be found in the articles by Eider et al [23,24]. 2% Nital-Nitric and Ethanol acid-to reveal the grain structure were used.…”

Section: Mechanical Characterization Of Additive Manufacturing Materialsmentioning

confidence: 99%

Model for the Prediction of Deformations in the Manufacture of Thin-Walled Parts by Wire Arc Additive Manufacturing Technology

Casuso

Veiga

Suárez

et al. 2021

Metals

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Gas Metal Arc Welding (GMAW) is a manufacturing technology included within the different Wire Arc Additive Manufacturing alternatives. These technologies have been generating great attention among scientists in recent decades. Its main qualities that make it highly productive with a large use of material with relatively inexpensive machine solutions make it a very advantageous technology. This paper covers the application of this technology for the manufacture of thin-walled parts. A finite element model is presented for estimating the deformations in this type of parts. This paper presents a simulation model that predicts temperatures with less than 5% error and deformations of the final part that, although quantitatively has errors of 20%, qualitatively allows to know the deformation modes of the part. Knowing the part areas subject to greater deformation may allow the future adaptation of deposition strategies or redesigns for their adaptation. These models are very useful both at a scientific and industrial level since when we find ourselves with a technology oriented to Near Net Shape (NNS) manufacturing where deformations are critical for obtaining the final part in a quality regime.

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“…The literature refers to various types of strategies, such as raster-pass, zigzag, contour or spiral in relation to material health, mechanical properties (such as strength and hardness) and geometric quality (shrinkage and warpage) [15][16][17][18]. The control of the volume of material deposited is also of great importance [19]. The most commonly-used strategies to achieve a constant deposition thickness are based on equidistant path generation methods [16,18,20].…”

Section: Introductionmentioning

confidence: 99%

Complex Interaction Between CMT Equipment and Robot Controllers During the WAAM Process: Consequences for Toolpath Accuracy

Viola

Balandraud

Poulhaon

et al. 2022

Preprint

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In the WAAM process, the accuracy of the toolpath is of prime importance for the mechanical properties of the final part because of the material defects that could be generated. This paper deals with the motion analysis of the end effector nozzle of a robot dedicated to the WAAM process. The movement of the nozzle to create a rectangular layer was experimentally analyzed without physically depositing material (trajectory definition only). Various strategies, nozzle speeds and layer areas were compared in terms of travel time and length over different sections of the toolpath in order to identify various problems, in particular associated with acceleration and deceleration phases when changing direction. The consequences of a discontinuous deposition were also studied, revealing a complex interaction between cold metal transfer equipment and robot controllers. The results enable a better understanding of this interaction, which is important for deposition quality and performance. Finally, a model was proposed to calculate the manufacturing time of any layer area based on a preliminary identification for a single area.

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High deposition wire arc additive manufacturing of mild steel: Strategies and heat input effect on microstructure and mechanical properties

Cited by 106 publications

References 22 publications

Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM

Transferability of the working envelope approach for parameter selection and optimization in thin wall WAAM

Model for the Prediction of Deformations in the Manufacture of Thin-Walled Parts by Wire Arc Additive Manufacturing Technology

Complex Interaction Between CMT Equipment and Robot Controllers During the WAAM Process: Consequences for Toolpath Accuracy

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