Influence of ultrasonic vibration on molten pool behavior and deposition layer forming morphology for wire and arc additive manufacturing

Ji, Feilong; Qin, Xunpeng; Hu, Zeqi; Xiong, Xiaochen; Ni, Mao; Wu, Mengwu

doi:10.1016/j.icheatmasstransfer.2021.105789

Cited by 49 publications

(12 citation statements)

References 32 publications

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“…This is due to the interruption of columnar crystals during growth by arc, shielding gas, surface tension, buoyancy, etc. [ 27 , 28 , 29 ]. These small grains prove that MIG welding has a certain effect on grain refinement.…”

Section: Resultsmentioning

confidence: 99%

Microstructure, Fatigue Properties and Stress Concentration Analysis of 6005 Aluminum Alloy MIG Welded Lap Joint

Yang

Zhao

et al. 2022

Materials

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This paper studies the microstructure and mechanical properties of MIG (Melt Inert Gas) lap welded 6005 aluminum alloy plates. Microstructure analysis (OM) of the joint showed that 15~30 μm small grains were observed at the fusion line. Mechanical analysis shows that the small grains are broken by shielding gas and molten pool flow force. Hardness test shows that there is a softening zone (41~43 HV) in HAZ much lower than BM and WZ. The low cycle fatigue test showed that the performance of lap joint decreased sharply, and the fatigue strength of weld decreased significantly, which was only 27.34% of the base metal. The fatigue fracture (SEM) of the weld observed slip band cracking and a large number of brittle fracture characteristics. Using the stress concentration factor Kt for analysis, it was found that the cause of brittle fracture was mostly stress concentration. Lap joint stress concentration model appears in two ways: firstly, at the weld toe, the weld is subjected to eccentric force, secondly, there is a small gap between the two plates at the weld root, which cracks along the direction of 45° of the maximum shear stress.

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Section: Resultsmentioning

confidence: 99%

Microstructure, Fatigue Properties and Stress Concentration Analysis of 6005 Aluminum Alloy MIG Welded Lap Joint

Yang

Zhao

et al. 2022

Materials

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“…Capillary waves are generated by the violent oscillation of the molten pool caused by ultrasonic vibration. However, the capillary wave is small in size and will be remelted by the next deposition, so it does not affect the formed appearance [ 44 ]. A small number of tiny pores appear on the surface of sample 3, and a larger number of pores gather on the surface at the arc-end point.…”

Section: Resultsmentioning

confidence: 99%

Effects of In-Process Ultrasonic Vibration on Weld Formation and Grain Size of Wire and Arc Additive Manufactured Parts

et al. 2022

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Wire and arc additive manufacturing (WAAM) is a competitive technique, which enables the fabrication of medium and large metallic components. However, due to the presence of coarse columnar grains in the additively manufactured parts, the resultant mechanical properties will be reduced, which limits the application of WAAM processes in the engineering fields. Grain refinement and improved mechanical properties can be achieved by introducing ultrasonic vibration. Herein, we applied ultrasonic vibration to the WAAM process and investigated the effects of wire feed speed, welding speed, and ultrasonic amplitude on the weld formation and grain size during ultrasonic vibration. Finally, a regression model between the average grain size and wire feed speed, welding speed, and ultrasonic amplitude was established. The results showed that due to the difference in heat input and cladding amount, wire feed speed, welding speed, and ultrasonic amplitude have a significant influence on the weld width and reinforcement. Excessive ultrasonic amplitude could cause the weld to crack during spreading. The average grain size increased with increasing wire feed speed and decreasing welding speed. With increasing ultrasonic amplitude, the average grain size exhibited a trend of decreasing first and then increasing. This would be helpful to manufacture parts of the required grain size in ultrasonic vibration-assisted WAAM fields.

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“…Numerous recent research works indicate that dendrite fragmentation and microstructure refinement in metal solidification processes with ultrasonic treatment are mainly ascribed to the cavitation effect of ultrasonic [21,35,36]. The cavitation effect is the result of the dynamic interaction between sound pressure and bubbles.…”

Section: Discussionmentioning

confidence: 99%

Ultrasonic-Induced Grain Refinement in Laser Cladding Nickel-Based Superalloy Reinforced by WC Particles

et al. 2023

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Laser cladding was used to prepare three composite coatings, i.e., Inconel 718 nickel-based superalloy (IN718), IN718-50 wt.% WC created by adding tungsten carbide (WC) particles and IN718-50 wt.% WC assisted by ultrasonic vibration. The phase composition, microstructure evolution, microhardness, residual stress and tribological properties of the three coatings were studied. The addition of WC enhances hardness and improves tribological properties, but also causes aggregation and considerable formation of carbides associated with rough structure. Ultrasonic vibration greatly refines the solidification microstructure, as it can break the growing dendrites, reduce the aggregation of reinforced particles and refine solidified structure. The average microhardness of the latter two composite coatings was increased by 36.37% and 57.15%, respectively, compared with the first IN718 coating, and the last composite coating (ultrasonic assistance) had the lowest COF (0.494). The WC particles and refined carbides converted the wear mechanism from adhesive wear to abrasive wear. In addition, the resultant stress on the surface of the composite coating roughly doubled after adding 50 wt.% WC, and only increased by 49.53% with ultrasonic treatment. The simulation results indicate that acoustic cavitation mainly occurs in the middle and bottom of the molten pool and proper frequency ultrasonic is conducive to the generation of the cavitation effect.

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Influence of ultrasonic vibration on molten pool behavior and deposition layer forming morphology for wire and arc additive manufacturing

Cited by 49 publications

References 32 publications

Microstructure, Fatigue Properties and Stress Concentration Analysis of 6005 Aluminum Alloy MIG Welded Lap Joint

Microstructure, Fatigue Properties and Stress Concentration Analysis of 6005 Aluminum Alloy MIG Welded Lap Joint

Effects of In-Process Ultrasonic Vibration on Weld Formation and Grain Size of Wire and Arc Additive Manufactured Parts

Ultrasonic-Induced Grain Refinement in Laser Cladding Nickel-Based Superalloy Reinforced by WC Particles

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