Process stability for GTAW-based additive manufacturing

Wang, Xiaolong; Wang, Aimin; Wang, Kaixiang; Li, Yuebo

doi:10.1108/rpj-02-2018-0046

Cited by 17 publications

(3 citation statements)

References 18 publications

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“…Additive manufacturing (AM) is an innovative production technology that has gathered the attention of researchers owing to its several benefits, ranging from its ability to manufacture peculiar and complex-shaped components, cutting off the use of additional tooling and fixtures and its ability to handle a wide range of metals, polymers and ceramics (Ngo et al , 2018). Among the seven derivatives of the AM process, wire arc additive manufacturing (WAAM) is a metal AM process that uses metallic wire as the feedstock material and electric arc as the heat source to melt, solidify and deposit the material layer upon layer in a predefined path (Wang et al , 2019; Chi et al , 2022). It belongs to the directed energy deposition (DED) family of AM, for which the first patent was filed in 1925, but the basic process of WAAM has been used to perform the local repair of damaged and worn-out components for decades (Williams et al , 2016).…”

Section: Introductionmentioning

confidence: 99%

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Kumar,

Mandal

2024

RPJ

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Purpose Wire-arc-based additive manufacturing (WAAM) is a promising technology for the efficient and economical fabrication of medium-large components. However, the anisotropic behavior of the multilayered WAAM-fabricated components remains a challenging problem. Design/methodology/approach The purpose of this paper is to conduct a comprehensive study of the grain morphology, crystallographic orientation and texture in three regions of the WAAM printed component. Furthermore, the interdependence of the grain morphology in different regions of the fabricated component with their mechanical and tribological properties was established. Findings The electron back-scattered diffraction analysis of the top and bottom regions revealed fine recrystallized grains, whereas the middle regions acquired columnar grains with an average size of approximately 8.980 µm. The analysis revealed a higher misorientation angle and an intense crystallographic texture in the upper and lower regions. The investigations found a higher microhardness value of 168.93 ± 1.71 HV with superior wear resistance in the bottom region. The quantitative evaluation of the residual stress detected higher compressive stress in the upper regions. Evidence for comparable ultimate tensile strength and greater elongation (%) compared to its wrought counterpart has been observed. Originality/value The study found a good correlation between the grain morphology in different regions of the WAAM-fabricated component and their mechanical and wear properties. The Hall–Petch relationship also established good agreement between the grain morphology and tensile test results. Improved ductility compared to its wrought counterpart was observed. The anisotropy exists with improved mechanical properties along the longitudinal direction. Moreover, cylindrical components have superior tribological properties compared with cuboidal components.

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Section: Introductionmentioning

confidence: 99%

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Kumar,

Mandal

2024

RPJ

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“…Today, nickel-based alloys are commonly fabricated using the WAAM technique in aerospace industries [2][3][4][5]. With GTAW-based WAAM, components have high quality, no splash, and reduced pollution [17,18].…”

Section: Introductionmentioning

confidence: 99%

Microstructural characterization and mechanical properties of Inconel 625 wall fabricated by GTAW-based WAAM using stringer bead and circular weave pattern

Akash,

Puviyarasan,

Senthil

et al. 2023

Eng. Res. Express

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In this work, Inconel 625 alloy was used to manufacture walls using the Wire Arc Additive Manufacturing (WAAM) technology, which is based on Gas Tungsten Arc Welding (GTAW). The wall was fabricated using a circular weave and stringer bead pattern. Microstructural analysis and tensile characteristics were evaluated for both walls. Using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and elemental mapping, the fracture zones of the tensile specimens were examined. The microstructure is mostly made up of equiaxed dendrites, with the rare presence of continuous and discontinuous cellular dendrites along the cross-section. In tensile tests, circular weaved walls performed better than stringer bead walls. The circular weave specimen had an ultimate tensile strength (UTS) of 762 MPa in the horizontal and 722 MPa in the vertical orientations. Also, the Inconel 625 wall showed anisotropic behavior (5.3%) during tensile testing. The fracture morphology analysis revealed that all the specimens were fractured as a result of large plastic deformation, corresponding to ductile failure. Based on the EDS results, the fracture zone mainly consists of Ni and Cr with a small percentage of Nb and Mo. The absence of laves phases makes the fracture mode ductile. The elemental mapping shows uniform dispersion of Ni and Cr within the fracture region, further supporting the ductile failure mode.

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“…Gas tungsten arc welding (GTAW) achieves additive manufacturing (AM) by adding a wire feeder. It has the advantages of a stable arc, high forming quality, no splashing, less pollution, and low cost [3,4]. The process parameters of GTAW-AM include the welding current, wire feeding speed, torch travel speed, wire feeding angle, tungsten electrode height, and flow rate of protective gas [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Study on the Relationship between Process Parameters and theFormation of GTAW Additive Manufacturing of TC4 Titanium Alloy Using the Response Surface Method

Liu,

Feng,

Chen

et al. 2023

Coatings

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The geometric parameters of the deposited layer include the width, height, and penetration depth of the deposited layer. The welding current, wire feeding speed, and torch travel speed during the additive manufacturing process of TC4 titanium alloy have the greatest impact on the geometric parameters of the deposited layer. In order to study how the deposition layer width, deposition layer height, and penetration depth are affected by the welding current, wire feeding speed, and torch travel speed, this article uses Design Expert 8.0.6 software for Box−Behnken design response surface experiments. During the experimental design, the welding current, wire feeding speed, and torch travel speed are used as input variables. The deposition layer width, deposition layer height, and penetration depth are selected as the responses. We designed 17 response surface experiments that were conducted using GTAW-AM. The results show that as the welding current increases, the penetration depth and width of deposition layer gradually increase, and the deposition layer height gradually decreases. As the wire feeding speed increases, the deposition layer height and penetration depth gradually increase, and the wire feeding speed has a minimal effect on the deposition layer width. As the torch travel speed increases, the penetration depth, width and height of deposition layer gradually decrease. The response surface method experimental design can also optimize the matching of three process parameters: welding current, wire feeding speed, and torch travel speed, thereby obtaining the optimal matching range of process parameters. Within the optimized matching range of process parameters, a welding current of 90 A, a wire feeding speed of 900 mm/min, and a torch travel speed of 200.18 mm/min were selected to prepare TC4 titanium alloy thin-walled part. The microstructure of the top, middle and bottom are all basketweave structure. The α phase gradually becomes coarse from the top to the bottom. The microhardness of the top, middle, and bottom of the thin-walled parts is 362.7 HV, 352.7 HV, and 340.5 HV, respectively. The horizontal tensile strength is 926.1 MPa, with an elongation of 12.22%, and the vertical tensile strength is 938.1 MPa, with an elongation of 14.41%.

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Process stability for GTAW-based additive manufacturing

Cited by 17 publications

References 18 publications

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

A critical investigation of the anisotropic behavior in the WAAM-fabricated structure

Microstructural characterization and mechanical properties of Inconel 625 wall fabricated by GTAW-based WAAM using stringer bead and circular weave pattern

Study on the Relationship between Process Parameters and theFormation of GTAW Additive Manufacturing of TC4 Titanium Alloy Using the Response Surface Method

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