Investigation of humping phenomenon for the multi-directional robotic wire and arc additive manufacturing

Yuan, Lei; Pan, Zengxi; Ding, Donghong; He, Fengyang; Duin, Stephen van; Li, Hui Jun; Li, Weihua

doi:10.1016/j.rcim.2019.101916

Cited by 49 publications

(17 citation statements)

References 32 publications

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“…Humping typically occurs when welding speed is high. 14,22 In this experimental study, travel speed is kept constant, whereas current and path planning (i.e. direction) is changed.…”

Section: Humping Defectmentioning

confidence: 99%

“…Other challenges are like heat accumulation, humping defect and residual stresses between the deposited layers (inter-layer) that significantly affect the development of the microstructure of the manufactured component. 3,14 Humping defect is common in WAAM samples fabricated using GMAW. 14 Bradstreet 15 reported that in GMAW process the humping defect happens due to improper selection of process parameters, heat input, travel speed, surface condition and chemical composition of the base metal.…”

Section: Introductionmentioning

confidence: 99%

“…3,14 Humping defect is common in WAAM samples fabricated using GMAW. 14 Bradstreet 15 reported that in GMAW process the humping defect happens due to improper selection of process parameters, heat input, travel speed, surface condition and chemical composition of the base metal. During the welding process surface tension force and fluid flow, patterns are mainly responsible for happening of humping pattern in the welding process.…”

Section: Introductionmentioning

confidence: 99%

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Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

Koli

Yuvaraj

Aravindan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

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“…Humping typically occurs when welding speed is high. 14,22 In this experimental study, travel speed is kept constant, whereas current and path planning (i.e. direction) is changed.…”

Section: Humping Defectmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

Koli

Yuvaraj

Aravindan

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…The upper limits of TS, in turn, which prevents humping formation, also increased. Yuan et al [18] claimed that the humping formation is correlated to a strong molten metal flow with high momentum, mainly affected by arc pressure, electromagnetic force and Marangoni force. As discussed by the authors, the increase in current (due to WFS) leads to a higher arc pressure and, consequently, to a greater impulse on the metal flow, facilitating the humping formation.…”

Section: Experimental Planning For Building the Reference Working Envelopementioning

confidence: 99%

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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“…erefore, almost any complex shape of metal parts can be produced [1][2][3][4][5][6][7][8]. is method has several advantages over traditional manufacturing methods such as environmental friendliness, high material utilization, and molding efficiency, as well as low manufacturing costs [9][10][11][12][13][14]. 3D printing is especially popular for applications related to biomedicine, shipbuilding, aerospace, mold production, and automobile manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Performances for Wear‐Resistant Steel through the WAAM Technology

Ying

Guo

et al. 2021

Advances in Materials Science and Engineering

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This work describes the wire arc additive manufacturing (WAAM) approach used to fabricate parts from wear-resistant steel. The microstructure, crystal structures, and mechanical properties of the resulting samples were thoroughly analyzed. The wear-resistant steel parts demonstrated good forming, no internal defects, good metallurgical bonding, and excellent wear resistance. The metallographic analysis confirmed that the main phase was ferrite. The microhardness of the sample along its cross section was uniform in both horizontal and vertical directions and equals to 464.7HV0.2 and 482.4 HV0.2, respectively. The average values of tensile strength, elongation ratio, and room temperature Charpy shock were equal to 945.3 MPa, 4.3%, and 5 J, respectively.

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Investigation of humping phenomenon for the multi-directional robotic wire and arc additive manufacturing

Cited by 49 publications

References 32 publications

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

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

Microstructure and Performances for Wear‐Resistant Steel through the WAAM Technology

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