Improving arc stability during wire arc additive manufacturing of thin-walled titanium components

Choudhury, Shakti Swaroop; Marya, Surendar; Amirthalingam, Murugaiyan

doi:10.1016/j.jmapro.2021.03.033

Cited by 23 publications

(5 citation statements)

References 18 publications

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“…Efficiency can be assessed through the ratio of the effective wall width to the maximum wall width; thus, the efficiency is 0.62, 0.76, and 0.56 for the CMT, CSC, and DCEN walls, respectively. Similar efficiency of the CMT printed walls was demonstrated in another researchers' work [26,37].…”

Section: Microstructuresupporting

confidence: 83%

“…In summary, it can be noted that there is no critical difference in the printed walls microstructure, thus the metal transfer at the investigated intervals of the transfer parameters primarily influences the geometrical properties of the manufactured structures. Therefore, although the other works on Ti-WAAM are generally based on the CMT transfer process [26,36,37], the CSC transfer appears to be the most suitable for thin-walled structure printing due to its width efficiency and sufficient arc stability.…”

Section: Microstructurementioning

confidence: 99%

“…Otani demonstrated that the arc wandering phenomenon can be confined by applying a high-frequency micro-oscillation to the tip of the welding torch [25]. Choudhury et al [26] researched the stability of the GMAW process during WAAM using surface treated commercially pure Ti wire and reported on a significant process improvement when using wire with an oxidized surface. Many works reported on Ti-GMAW stabilization using laser beam-arc stabilization was defined as the lack of cathode spot motion, the cathode spot position was confined to the laser beam focus spot location [23,27].…”

Section: Introductionmentioning

confidence: 99%

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Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

et al. 2021

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In wire arc additive manufacturing of Ti-alloy parts (Ti-WAAM) gas metal arc welding (GMAW) can be applied for complex parts printing. However, due to the specific properties of Ti, GMAW of Ti-alloys is complicated. In this work, three different types of metal transfer modes during Ti-WAAM were investigated: Cold Metal Transfer, controlled short circuiting metal transfer, and self-regulated metal transfer at a direct current with a negative electrode. Metal transfer modes were studied using captured waveform and high-speed video analysis. Using these modes, three walls were manufactured; the geometry preservation stability was estimated and compared using effective wall width calculation, the microstructure was analyzed using optical microscopy. Transfer process data showed that arc wandering depends not only on cathode spot instabilities, but also on anode processing properties. Microstructure analysis showed that each produced wall consists of phases and structures inherent for Ti-WAAM. α-basketweave in the center of and α-colony on the grain boundary of epitaxially grown β-grains were found with heat affected zone bands along the height of the walls, so that the microstructure did not depend on metal transfer dramatically. However, the geometry preservation stability was higher in the wall, produced with controlled short circuiting metal transfer.

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Section: Microstructuresupporting

confidence: 83%

Section: Microstructurementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

et al. 2021

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“…This means that the process parameters that govern the quality of specimens must be carefully optimized, as the required parameters differ for different grades of materials. Controlling these variables for a suitable multi-layered structure is essential [ 17 ]. Two important characteristics of bead morphologies are bead width (BW) and bead height (BH).…”

Section: Introductionmentioning

confidence: 99%

Fabrication of Multi-Walled Structure through Parametric Study of Bead Geometries of GMAW-Based WAAM Process of SS309L

Vora,

Pandey,

Dodiya

et al. 2023

Materials

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In the present study, an attempt is made to investigate and optimize the bead geometries of bead width (BW) and bead height (BH) of SS-309L using an SS316L substrate by employing a gas metal arc welding (GMAW)-based wire-arc additive manufacturing (WAAM) process. The Box–Behnken design approach was used to conduct the trials of single-layer depositions with input variables of travel speed (TS), voltage (V), and gas mixture ratio (GMR). The developed multi-variable regression models were tested for feasibility using ANOVA and residual plots. The data obtained indicated that V had the most significant impact on BW, followed by TS and GMR. For BH, TS had the most significant impact, followed by GMR and V. The results of single-response optimization using a passing vehicle search (PVS) algorithm showed a maximum BH of 9.48 mm and a minimum BW of 5.90 mm. To tackle the contradictory situation, a multi-objective PVS algorithm was employed, which produced non-dominated solutions. A multi-layered structure was successfully fabricated at the optimal parametric settings of TS at 20 mm/s, of voltage at 22 V, and of GMR at 3. For multi-layer structures, fusion among the layers was observed to be good, and they were found to be free from the disbonding of layers. This revealed the suitability of the PVS algorithm for generating suitable optimal WAAM variables. We consider the current work highly beneficial for users fabricating multi-layer structures.

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“…The single-pass multi-layer stacking method is generally used in fabricating thinwalled components. In this case, the arc shape is different from the ordinary welding arc; the arc usually elongates over the sidewall along the deposition direction [27]. Different wall thicknesses mean different arc shapes, resulting in different arc parameter distributions on the upper surface and sidewalls of the deposited wall, affecting the microstructure and properties of the deposited wall.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing

Zhou

Zhang

Peng

et al. 2022

Metals

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The single-pass multi-layer depositing strategy is usually used to fabricate thin-wall structures with wire and arc additive manufacturing (WAAM) technology. Various deposited wall thicknesses often lead to a change in arc shrinkage in the wall thickness direction, which affects the arc shape and stability, and even the microstructure and properties. To systematically study the effect of wall thickness (δ) on arc shape and stability, 3D numerical models were established, with wall thickness varying from 1 to 14 mm during the WAAM process. The characteristics of the arc shape, temperature field, velocity field, current density, and the electromagnetic force were investigated. When δ is smaller than the arc diameter (Φ), the thinner wall will result in a longer arc along the deposition direction. When δ is greater than the Φ, the arc shape tends to be a bell shape. When δ < Φ, the peak temperature in the arc centre, the peak current density, and the electromagnetic intensity along the welding direction decreased with the increase in the wall thickness. However, the opposite observations were found when δ < Φ. The simulation results are consistent with the actual arc shape collected and showed that when δ is slightly less than Φ, the forming quality of the deposited wall is the best. The research in this paper can fill the research gap and provide a theoretical basis for the matching selection of process parameters and wall thickness in WAAM applications.

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Improving arc stability during wire arc additive manufacturing of thin-walled titanium components

Cited by 23 publications

References 18 publications

Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

Fabrication of Multi-Walled Structure through Parametric Study of Bead Geometries of GMAW-Based WAAM Process of SS309L

Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing

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