Study on the thermal cycle of Wire Arc Additive Manufactured (WAAM) carbon steel wall using numerical simulation

Saadatmand, Mohsen; Talemi, Reza

doi:10.3221/igf-esis.52.08

Cited by 13 publications

(5 citation statements)

References 15 publications

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“…[ 5 ] Due to the presence of residual heat in the fabricated sample, the latter layers are fabricated at an increasing interlayer temperature. [ 30 ] Hence, the heat transfer capability of the substrate is further limited, and the heat accumulation is exacerbated. Thus, each layer has different thermal histories.…”

Section: Resultsmentioning

confidence: 99%

“…Compared with these zones, the layer band has the farthest distance to the heat source and thus the lowest peak temperature and cooling rate. [ 30,34 ] As shown in Figure 3, when depositing the water‐bath sample, both peak temperature and cooling rate of the substrate decrease, and every layer has a similar thermal cycle to the substrate because of the elimination of heat accumulation. During the solidification of the layer bands, austenite can transfer to both EF and LB.…”

Section: Discussionmentioning

confidence: 99%

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Effect of Modified Water‐Bath Method on Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Low‐Carbon Low‐Alloy Steel

Luo

You

et al. 2021

steel research int.

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Of late, wire arc additive manufacturing (WAAM) is extensively used in the aerospace and automotive fields to produce large complex metallic components. The water‐bath method is applied for active cooling to address the heat accumulation problem in WAAM. Herein, the modified water‐bath method with a changing level is used to realize different phase transformations, and the microstructure and mechanical properties of the sample are investigated. Heat accumulation in the sample is eliminated using the modified water‐bath method. Furthermore, the microstructure of the fabricated sample shows a mixture of polygonal ferrite (PF), upper bainite (UB), and lath bainite (LB). Layer bands are formed in the entire sample, except in the final layer, and equiaxed ferrite (EF) and an increased fraction of PF appear in these zones. The microhardness and tensile property are enhanced due to the fine LB. The considerable difference in the microhardness between LB and PF causes an obvious wave of hardness, and the tensile property along the horizontal direction is better than the vertical. This study is expected to help broaden the application of the water bath in the microstructure control.

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Section: Resultsmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Effect of Modified Water‐Bath Method on Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Low‐Carbon Low‐Alloy Steel

Luo

You

et al. 2021

steel research int.

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“…[ [58][59][60][61]103,141] Preheating substrate (Baseplate) Preheating the substrate in WAAM processes offers several benefits for managing RS in the final products. By reducing thermal gradients, mitigating distortion, improving metallurgical [97,142,143] bonding, enhancing ductility, and optimizing cooling rates, preheating helps to create parts with lower levels of RS and improved mechanical properties.…”

Section: Deposition Of Layer Time Dwell Time Between Layersmentioning

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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“…In addition, 3D coupled FE models for temperature distribution, residual stress, and deformation calculations were developed, as indicated by Cheng et al [208] and Parry et al [209], during the deposition process. The FEA calculations can be carried out using commercial software, such as ABAQUS [210], ANSYS [211], Simufact [212], or MSC Marc [213]. The thermal and mechanical analysis was performed to obtain the temperature distribution and residual stresses.…”

Section: Thermo-mechanical Analysismentioning

confidence: 99%

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Kumar

Manikandan

2021

Met. Mater. Int.

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Wire arc additive manufacturing (WAAM) technique became an emerging manufacturing technology because of its costeffective in creating large-scale metal parts with moderately high deposition rates. Mainly, WAAM works through the utilization of heat source as an electric arc by melting the metal wire to build the three-dimensional metal parts in a layer-by-layer approach, which may significantly minimize the fabrication costs compared to powder and other additive manufacturing techniques such as laser and electron beam, similarly. This article reviews WAAM processes and methods and gives an exhaustive overview of the residual stresses, microstructures, and material properties of the as-fabricated and post-fabrication treated WAAM components. The typical defects during the fabrication of metal components by the WAAM process are residual stresses, deformity, porosity, and cracking. And also, methods on controlling residual stresses, improving material properties, and effects of post-processing treatments to enhance the part quality fabricated by using the WAAM process are recommended in this review. Finally, the measurement methods of residual stresses in the metal parts and FEA simulations in the WAAM are discussed. FEA simulations provide better insights on moving heat source model, temperature distributions, and residual stresses in the WAAM process. This article concludes that selecting process parameters affects the quality WAAM component during the deposition process. And also, approaches to improving the part quality are proposed. The materials fabrication issues in the WAAM processes were outlined, and the advanced WAMM processes were suggested to obtain high quality and defect-free WAAM parts.

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Study on the thermal cycle of Wire Arc Additive Manufactured (WAAM) carbon steel wall using numerical simulation

Cited by 13 publications

References 15 publications

Effect of Modified Water‐Bath Method on Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Low‐Carbon Low‐Alloy Steel

Effect of Modified Water‐Bath Method on Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Low‐Carbon Low‐Alloy Steel

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

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

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