Review of post-processing methods for high-quality wire arc additive manufacturing

Bankong, B. D.; Abioye, T.E.; Olugbade, Temitope Olumide; Hussain, Zuhailawati; Gbadeyan, O.O.; Ogedengbe, T.I.

doi:10.1080/02670836.2022.2110223

Cited by 13 publications

(2 citation statements)

References 86 publications

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“…Finite element process simulation offers an effective method to explore strategies to mitigate these distortions and RS [174]. Some methods provided techniques to handle RS, enhance mechanical properties, and eliminate defects like porosity [31,175]. Some common mitigation strategies and practical applications are listed and explained with practical application in Table 4.…”

Section: Mitigation Strategies For Rs In Waam and Practical Applicationsmentioning

confidence: 99%

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Gurmesa,

Lemu,

Adugna

et al. 2024

Preprint

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This literature review provides an in-depth exploration of the research conducted on the investigation and measurement of residual stress (RS) in Wire Arc Additive Manufacturing (WAAM) products, particularly focusing on how process parameters influence the phenomenon. RS plays a crucial role in determining the mechanical behavior and structural integrity of WAAM components. This review article gives an understanding of the relationship between process parameters and RS to optimize the WAAM processes and ensure the durability of the final products. It also summarizes key findings, measurement techniques, challenges, and future directions in this evolving field. The review also analyzes a measurement of RS in the products of WAAM as a function of process parameters depending on examining various research studies, techniques, and methodologies employed in their studies. Experimental measuring techniques and numerical analysis of RS to determine the impacts of RS in mechanical response in products of WAAM were discussed. By offering a comprehensive overview of current research trends and insights, this review serves as a valuable resource to guide future investigations, fostering the advancement of WAAM as a robust and efficient manufacturing technology.

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Section: Mitigation Strategies For Rs In Waam and Practical Applicationsmentioning

confidence: 99%

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Gurmesa,

Lemu,

Adugna

et al. 2024

Preprint

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“…A welding unit with a wire feeder and robot-controlled by a central computer are the basic components of CMT-WAAM. This technique has superior mechanical properties compared with GMAW-WAAM for manufacturing low-carbon steel components [12]. In spite of these merits, internal defects and defective layers are the common problems encountered with CMT-WAAM.…”

Section: Introductionmentioning

confidence: 99%

A hybrid approach consisting of multi-objective and multivariate analyses for WAAM specimens

2023

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In this study, a combination of multivariate and multi-objective analyses, namely principal component analysis with fuzzy logic, has been proposed to identify the input parameters for ER4043, aluminum alloy in wire arc additive manufacturing. Taguchi L9 orthogonal array was designed with three-factor, three-level input parameters. Mechanical properties such as tensile strength and hardness were used as the output parameters. As the Taguchi optimization is not sufficient for multi-response optimization, observed data for each response were normalized and then principal component analysis was applied. Further, multi-response performance index (MRPI) was identified using fuzzy logic approach so that this hybrid approach could be successfully applied and MRPI could give a combination of input parameters at an optimal level.

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Preventing columnar grains growth during hybrid wire arc additive manufacturing of austenitic stainless steel 316L

Albannai,

León‐Henao,

Ramirez

2024

Engineering Reports

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Wire arc additive manufacturing (WAAM) is an efficient technique for producing medium to large‐size components, due to its accessibility and sustainability in fabricating large‐scale parts with high deposition rates, employing low‐cost and simple equipment, and achieving high material efficiency. Consequently, WAAM has garnered attention across various industrial sectors and experienced significant growth, particularly over the last decade, as it addresses and mitigates challenges within production markets. One of the primary limitations of WAAM is its thermal history during the process, which directly influences grain formation and microstructure heterogeneity in the resulting part. Understanding the thermal cycle of the WAAM process is thus crucial for process improvement. Typically, fabricating a part using WAAM results in a microstructure with three distinct zones along the build direction: an upper zone (thin surface layer) with fine grains, a middle zone dominated by undesirably long and large columnar grains covering more than 90% of the produced part, and a lower zone with smaller to intermediate columnar grains closer to the substrate material. These zones arise from variations in cooling rates, with the middle zone exhibiting the lowest cooling rate due to 2D conduction heat transfer. Consequently, producing a component with a microstructure comprising three different zones, with a high fraction of large and long columnar grains, significantly impacts the final mechanical properties. Therefore, controlling the size and formation of these grain zones plays a key role in improving WAAM. The aim of this work is to investigate the formation of undesired columnar grains in austenitic stainless steel 316L during WAAM and propose a simple hybrid technique by combining WAAM with a hot forging process (with or without interlayer cooling time). This approach targets the disruption of the solidification pattern of columnar grain growth during deposition progression and aims to enhance the microstructure of WAAM components.

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Review of post-processing methods for high-quality wire arc additive manufacturing

Cited by 13 publications

References 86 publications

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

Review of Measuring Methods of Residual Stress in Wire Arc Additive Manufacturing Products

A hybrid approach consisting of multi-objective and multivariate analyses for WAAM specimens

Preventing columnar grains growth during hybrid wire arc additive manufacturing of austenitic stainless steel 316L

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