Thermal modeling and characterization of wire arc additive manufactured duplex stainless steel

Hejripour, Fatemeh; Binesh, Farrokh; Hebel, Mark; Aidun, D. K.

doi:10.1016/j.jmatprotec.2019.05.003

Cited by 96 publications

(35 citation statements)

References 30 publications

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“…In addition, to analyze the effect of the mass flow, the domain activation method [11] was used in the simulation, which simplifies the element activation method [13,17]. In AM process analysis, the element activation method is applied to simulate the shape of the deposit that changes in real time due to mass flow.…”

Section: Finite Element Modelmentioning

confidence: 99%

“…However, during simulation, the computational load becomes extensive because activation and deactivation are performed sequentially for each element. Therefore, in this study, each layer was divided into four equally sized domains considering the computational load [11]. As shown in Figure 3b, for the initial temperature of the activated domain, the temperature calculated in the previous layer was applied.…”

Section: Finite Element Modelmentioning

confidence: 99%

“…Few researchers are attempting to simulate the thermal characteristics of WAAM. F. Hejripour et al [11] used 2209 duplex stainless steel (DSS) to manufacture wall-and tube-shaped deposits with the WAAM process, and developed 3D numerical thermal models to analyse the temperature history and cooling rate of each deposit layer; they stated that ferrite to austenite transformation was promoted, when the cooling rate of each deposit layer was below 50 • C/s. Jun et al [12] fabricated a circular wall deposit with WAAM using mild steel, and developed a 3D transient heat transfer model; applying this model, they reported that the maximum temperature gradient, when the heat source passes through the centre of the layer during deposition was quantified for each layer.…”

Section: Introductionmentioning

confidence: 99%

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CMT-Based Wire Arc Additive Manufacturing Using 316L Stainless Steel: Effect of Heat Accumulation on the Multi-Layer Deposits

Lee

2020

Metals

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CMT welding sources are garnering attention as alternative heat sources for wire arc additive manufacturing because of their low-heat input. A comprehensive experimental and numerical study on the multi-layer deposition of STS316L was performed to investigate effect of heat accumulation during the deposition. The numerical model which is appropriate for WAMM was developed considering the characteristics of the CMT heat source for the first time. Using a high-speed camera, the transient behavior of the CMT arc was investigated, and applied to the heat source of the numerical model. The model was then used to analyze 10-layered deposits of STS316L, fabricated using CMT-based WAAM. During deposition, the temperature is measured using a pyrometer to analyze the microstructure, after which the cooling rate of each layer is estimated. The measured and simulated SDAS were compared. Based on the comparison, a guideline for the equation regarding the SDAS size and cooling rate was suggested.

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Section: Finite Element Modelmentioning

confidence: 99%

Section: Finite Element Modelmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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CMT-Based Wire Arc Additive Manufacturing Using 316L Stainless Steel: Effect of Heat Accumulation on the Multi-Layer Deposits

Lee

2020

Metals

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“…There are a very few studies available for duplex stainless steel (22Cr5Ni) consisting of approximately 50% ferrite and 50% austenite. It was reported [26] that the ferrite content in subsequently deposited layers is reduced along with hardness compared to the support plate. Stützer et al [27] used a new approach for estimation of ferrite (α)/austenite (γ) balance with different wires and CMT technology and achieved a balance of 50%/50% of austenite and ferrite with good mechanical and corrosion properties.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing with Superduplex Stainless Steel Wire by CMT Process

Lervåg

Sørensen

Robertstad

et al. 2020

Metals

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For many years, the oil and gas industry has utilized superduplex stainless steels due to their high strength and excellent corrosion resistance. Wire arc additive manufacturing (WAAM) was used with superduplex filler wire to create walls with different heat input. Due to the multiple heating and cooling cycles during layer deposition, brittle secondary phases may form such as intermetallic sigma (σ) phase. By inspecting deposited walls within wide range of heat inputs (0.40–0.87 kJ/mm), no intermetallic phases formed due to low inter-pass temperatures used, together with the high Ni content in the applied wire. Lower mechanical properties were observed with high heat inputs due to low ferrite volume fraction, precipitation of Cr nitrides and formation of secondary austenite. The walls showed good toughness values based on both Charpy V-notch and CTOD (crack tip opening displacement) testing.

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“…* The WAAM process was also referred as DWF-PAM, SWF-PAM, GMAW-CMT, and CMT in different papers. Similarly, Hejripour et al used GMA-WAAM to fabricate 2209 duplex stainless steel (DSS) walls and tubes, and indicated that calculation of cooling rates in deposited layers could help forecast the formation of the phases [105]. Their numerical and experimental results revealed that austenite formation could be significantly promoted by slow cooling rates in the layers at elevated temperatures.…”

Section: Microstructurementioning

confidence: 99%

Wire Arc Additive Manufacturing of Stainless Steels: A Review

et al. 2020

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Wire arc additive manufacturing (WAAM) has been considered as a promising technology for the production of large metallic structures with high deposition rates and low cost. Stainless steels are widely applied due to good mechanical properties and excellent corrosion resistance. This paper reviews the current status of stainless steel WAAM, covering the microstructure, mechanical properties, and defects related to different stainless steels and process parameters. Residual stress and distortion of the WAAM manufactured components are discussed. Specific WAAM techniques, material compositions, process parameters, shielding gas composition, post heat treatments, microstructure, and defects can significantly influence the mechanical properties of WAAM stainless steels. To achieve high quality WAAM stainless steel parts, there is still a strong need to further study the underlying physical metallurgy mechanisms of the WAAM process and post heat treatments to optimize the WAAM and heat treatment parameters and thus control the microstructure. WAAM samples often show considerable anisotropy both in microstructure and mechanical properties. The new in-situ rolling + WAAM process is very effective in reducing the anisotropy, which also can reduce the residual stress and distortion. For future industrial applications, fatigue properties, and corrosion behaviors of WAAMed stainless steels need to be deeply studied in the future. Additionally, further efforts should be made to improve the WAAM process to achieve faster deposition rates and better-quality control.

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Thermal modeling and characterization of wire arc additive manufactured duplex stainless steel

Cited by 96 publications

References 30 publications

CMT-Based Wire Arc Additive Manufacturing Using 316L Stainless Steel: Effect of Heat Accumulation on the Multi-Layer Deposits

CMT-Based Wire Arc Additive Manufacturing Using 316L Stainless Steel: Effect of Heat Accumulation on the Multi-Layer Deposits

Additive Manufacturing with Superduplex Stainless Steel Wire by CMT Process

Wire Arc Additive Manufacturing of Stainless Steels: A Review

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