Multi-heat input technique for aluminum WAAM using DP-GMAW process

Greebmalai, Jukkapun; Warinsiriruk, Eakkachai

doi:10.1063/5.0022954

Cited by 5 publications

(3 citation statements)

References 4 publications

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“…Other equivalent research conducted an investigation to compare final distortion and longitudinal residual stress stating that DC induced 5 mm distortion and 1,100 MPa residual stress whilst pulsed current 3 mm and 500 MPa (Suder et al, 2009). Furthermore, the experimental WAAM process with pulsed current indicated 14% lower material usage compare to other deposition methods (Junyi, 2020) which confirmed the relatively similar results with 20% overall lower deposition and 4% lower height (Greebmalai and Warinsiririkuk, 2020).…”

supporting

confidence: 65%

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Prajadhiana

Manurung

Bauer

et al. 2021

RPJ

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Purpose This paper aims to numerical and experimental analysis on substrate deformation and plastic strain induced by wire arc additive manufacturing. Design/methodology/approach The component has the form of a hollow, rectangular thin wall consisting of 25 deposition layers of SS316L on an SS304 substrate plate. Thermo-mechanical finite element analysis was applied with Goldak’s double-ellipsoidal heat-source model and a non-linear isotropic hardening rule based on von Mises’ yield criterion. The layer deposition was modelled using simplified geometry to minimize overall pre-processing work and computational time. Findings A new material modelling of SS316L was obtained from the chemical composition of the evolved component characterized by scanning electron microscope/energy dispersive X-ray and further generated by an advanced material-modelling software JMatPro. In defining heat-transfer coefficients, transient thermometric analysis was first performed in the bead and on the substrate, which was followed by an adjustment of the heat-transfer coefficients to reflect the actual temperature distribution. Based on the adjusted model and boundary conditions, sensitivity analysis was conducted prior to the ultimate simulation of substrate deformation and equivalent plastic strain. Furthermore, this simulation was verified by conducting a series of automated wire + arc additive manufacturing tests using robotic gas Metal arc welding with distortion measured by coordinate-measurement machine and equivalent plastic strain measured by optical three-dimensional-metrology measurements (Gesellschaft für Optische Messtechnik). Originality/value It can be concluded that a proper numerical computation using the adjusted model and property-evolved material exhibits a similar trend with acceptable agreement compared to the experiment by yielding an error percentage up to 30% for deformation and up to 21% for equivalent plastic strain at each individual measurement point.

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supporting

confidence: 65%

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Prajadhiana

Manurung

Bauer

et al. 2021

RPJ

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“…Humping is a common defect in WAAM samples fabricated using GMAW [109]. Humping defect also plays a major role in the reduction of hardness and tensile strength of the fabricated WAAM sample [110,111]. As discussed by Wu et al.…”

Section: Challenges Facing the Application Of Waam In Aerospace And A...mentioning

confidence: 99%

Wire arc additive manufacturing of aluminium alloys for aerospace and automotive applications: A review

Omiyale

Olugbade

Abioye

et al. 2022

Materials Science and Technology

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Wire arc additive manufacturing (WAAM) is suitable for printing medium-to-large complex parts with structural integrity while reducing material wastage, and lead time, improving the quality and customized design for functional components. Aluminium alloys are one of the most commonly used metallic materials in manufacturing parts for aerospace and automotive applications due to their lightweight, excellent strength, and corrosion resistance properties. Aluminium alloys have been employed in the WAAM process to produce parts for the aerospace and automotive industries. In this paper, various research works associated with the application of WAAM of aluminium alloys for aerospace and automotive industries, their metallurgical characteristics, and mechanical properties have been reviewed and discussed in detail to identify the research gap and future research directions. This paper is patterned to provide a comprehensive review of WAAM of aluminium alloys for the production of parts in the aerospace and automotive industries. Abbreviations: AM: Additive manufacturing; Al: Aluminium; Bi: Bismuth; BIW: Body in white; CNC: Computer numerical machines; CMT: Cold metal transfer; CNN: Convolutional neural networks; CL: Curved layer; DE-GMAAM: Double-electrode gas metal arc additive manufacturing; DWAAM: Double wire arc additive manufacturing; DMD: Direct metal deposition; DMLS: Direct metal laser sintering; DED-arc: Directed energy deposition arc; 3D: Three-dimensional; EAC: Environmentally assisted cracking; EBM: Electron beam melting; FCI: Fatigue crack initiation; Fe: Iron; GTAW: Gas tungsten arc welding; GMAW: Gas metal arc welding; HE: Hydrogen embrittlement; HAZ: Heat-affected zone; HWAAM: Hot wire arc additive manufacturing; IISCC: Irradiation induced stress corrosion cracking; Li: Lithium; Mg: Magnesium; Mn: Manganese; Ni: Nickel; OL: Online cooling; Pb: Lead; PAW: Plasma arc welding; RS: Robotic system; SCC: Stress corrosion cracking; SLM: Selective laser melting; SCG: Short crack growth; SLC: Super light car; Si: Silicon; Ti: Titanium; Zr: Zirconium

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“…Gas Metal Arc Welding (GMAW) is the most commonly used energy source in WAAM because GMAW-based additive manufacturing has several advantages, the most important of which is lower cost (Chernovol et al, 2020;Giarollo et al, 2022;Navarro et al, 2021;Van Thao, 2020). In addition, the technique offers a high deposition rate (Chaturvedi et al, 2021;Nagasai et al, 2021;Paskual et al, 2018;Shen et al, 2020;Van Thao, 2020) and high welding efficiency, that is, material and energy (Giarollo et al, 2022;Greebmalai & Warinsiriruk, 2020;Henckell et al, 2020;Paskual et al, 2018;Reisgen et al, 2020). GMAW is more suitable for medium and large components (Feucht et al, 2021;Gierth et al, 2020;Pandey, 2019;Waldschmitt, 2019).…”

Section: Introductionmentioning

confidence: 99%

Bead Geometry Control in Wire Arc Additive Manufactured Profile — A Review

Wani,

Abdullah

2024

JST

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Wire arc additive manufacturing (WAAM) is a well-established additive manufacturing method that produces 3D profiles. A better deposition efficiency can be achieved by understanding the parameters that may influence the geometry of the bead. This paper provides a review that focuses on the factors that may influence the formation of the 3D profile. The included factors are the flow pattern of the molten pool after deposition, the built structure and orientation, the heat input and cooling conditions, the welding parameters, and other uncertainties. This review aims to facilitate a better understanding of these factors and achieve the optimum geometry of the 3D parts produced. According to the literature, the behavior of molten pools is identified as one of the major factors that can impact the deposition efficiency of a bead and govern its geometry. The review indicated that the flow behavior of the molten pool and the geometry of the deposited bead are significantly affected by most welding parameters, such as torch angle, wire travel speed, filler feed rate, and cooling conditions. Furthermore, this paper incorporates the technology utilized for comprehending the behaviors of the molten pool, as it constitutes an integral component of the control strategy. It has been concluded that automated planning and strategy are necessary to ensure efficient deposition by controlling those factors. The integration of artificial intelligence could bring benefits in planning to address the variation and complexity of shapes.

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Multi-heat input technique for aluminum WAAM using DP-GMAW process

Cited by 5 publications

References 4 publications

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Wire arc additive manufacturing of aluminium alloys for aerospace and automotive applications: A review

Bead Geometry Control in Wire Arc Additive Manufactured Profile — A Review

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