Wire Arc Additive Manufacturing – A revolutionary method in additive manufacturing

Kumar, Nilesh; Bhavsar, Het; Mahesh, P.V.S.; Srivastava, Ashish Kumar; Bora, Bhaskor Jyoti; Saxena, Ambuj; Dixit, Amit Rai

doi:10.1016/j.matchemphys.2022.126144

Cited by 50 publications

(22 citation statements)

References 173 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Linear wall samples were fabricated by using CMT and the pulsed method. The penetration and weldability are related to travel speed and the material’s conductivity [ 38 ]. The selection of the WAAM parameters must result in adequate heat input for the material to be welded.…”

Section: Methodsmentioning

confidence: 99%

Characterization of 5356 Aluminum Walls Produced by Wire Arc Additive Manufacturing (WAAM)

et al. 2023

View full text Add to dashboard Cite

Wire arc additive manufacturing (WAAM) is renowned for its high deposition rate, enabling the production of large parts. However, the process has challenges such as porosity formation, residual stresses, and cracking when manufacturing aluminum parts. This study focuses on ana-lyzing the porosity of AA5356 walls manufactured using the WAAM process with the Fronius cold metal transfer system (Wels, Austria). The walls were machined to obtain specimens for tensile testing. The study used computed tomography and the tensile test to analyze the specimens’ porosity and its potential relation to tensile strength. The process parameters analyzed were travel speed, cooling time, and path strategy. In conclusion, increasing travel speed and cooling time significantly affects pore diameter due to the lower heat input to the weld zone. Porosity can be reduced when diminishing heat accumulation. The results indicate that an increase in travel speed produces a slight decrease in porosity. Specifically, the total pore volume diminishes from 0.42 to 0.36 mm3 when increasing the travel speed from 700 to 950 mm/min. The ultimate tensile strength and maximum elongation of the ‘back and forth’ strategy are slightly higher than those of the ‘go’ strategy. After tensile testing, the ultimate tensile strength and yield strength did not show any relation to the porosity measured by computed tomography. The percentage of the pore total volume over the measured volume was lower than 0.12% for all the scanned specimens.

show abstract

Section: Methodsmentioning

confidence: 99%

Characterization of 5356 Aluminum Walls Produced by Wire Arc Additive Manufacturing (WAAM)

et al. 2023

View full text Add to dashboard Cite

show abstract

“…In the last years, the focus of ongoing research work changed from basic feasibility studies into the production of complex components. This included research into material behavior in the area of microstructure, isotropy behavior, and analysis of the mechanical technological quality values of the machined "ideal test specimens" [13]. The current research trend is aimed at analyzing the partially unprocessed additively manufactured components in realistic load conditions.…”

Section: Am Of Metallic Componentsmentioning

confidence: 99%

The effects of building position on surface and fatigue of DED-arc steel components

et al. 2022

View full text Add to dashboard Cite

Recently, additive manufacturing (AM) of structural metallic components is analyzed regarding its potential use by industry and research. Next to the development of manufacturing processes, the mechanical properties are under investigation today. One of the quality measures of metallic components is the surface topography. DED-arc processes (direct energy deposition) result in relatively coarse surfaces, characterized by a distinct waviness with wave amplitudes in the mm-range. This is enhanced when applying horizontal building position in comparison to vertical position. Next to increased waviness, the load-bearing net cross sections are reduced as well. The surface topography determines the fatigue life properties of metallic components. While stress raising surface effects are generally well understood and fatigue (Structures 31: 576–589, 2021) of welded metals is established well, the fatigue behaviour of additively manufactured components is less investigated yet. In order to define surface quality levels for DED-arc components, the effects of surface topography on mechanical performance need to be understood. This article presents the manufacturing of high strength steel test coupons by the DED-arc process. The process parameters were varied with regard to the building position and different levels of surface quality were generated. The surfaces of different specimens were characterized and fatigue tests were conducted. The results were used to derive the surface influence on both, the effective load-bearing wall thickness and notch effects induced by the layer-by-layer building approach. A correlation between building position, surface waviness and fatigue strength was proven. In general, higher waviness resulted in reduced effective wall thickness and lowered fatigue strength. A difference in fatigue strength at 2 million load cycles of 20 to 30% was proven when printing in different building positions. The surface effect can be captured in the design concept when applying the effective notch stress approach with an averaging length of of ρ* = 0.4 mm. The fatigue strength is describable by a design S–N curve FAT160 and a k-value of 4.

show abstract

“…One of the possible approaches to obtain evenly applied GMAW coating is to use a technique called WAAM—Wire Arc Additive Manufacturing [ 17 ]. It relies on adding consecutively applied weld beads, where the welding gun position is controlled numerically [ 18 ].…”

Section: Introductionmentioning

confidence: 99%

On the Influence of Linear Energy/Heat Input Coefficient on Hardness and Weld Bead Geometry in Chromium-Rich Stringer GMAW Coatings

et al. 2022

View full text Add to dashboard Cite

Wear of the working surfaces of machinery parts is a phenomenon that cannot be fully countered, only postponed. Among surface lifecycle elongation techniques, hardfacing is one which is most often used in heavy load applications. Hardfaced coating can be applied using different welding approaches or thermal spraying technologies, which differ when it comes to weld bead dimensional precision, layer thickness, process efficiency and material. In this study the authors examine the geometrical behavior and hardness properties of two distinctive chromium-based Gas Metal Arc Welding (GMAW) cored wires. The stringer beads are applied numerically with five levels of linear energy, being a resultant of typical values of welding speed and wire feed, ranging between 250 mm/s to 1250 mm/s (welding speed) and 2 m/min to 10 m/min (wire feed). The samples were cut, etched and measured using a digital microscope and Vickers indenter, additionally the chemical composition was also examined. Hardness was measured at five points in each cutout, giving 40 measurements per sample. The values were analyzed using an ANOVA test as a statistical background in order to emphasize the divergent behavior of the cored wires. It appeared that, despite having less chromium in its chemical composition, wire DO*351 exhibits higher hardness values; however, DO*332 tends to have a more stable geometry across all of the heat input levels.

show abstract

Wire Arc Additive Manufacturing – A revolutionary method in additive manufacturing

Cited by 50 publications

References 173 publications

Characterization of 5356 Aluminum Walls Produced by Wire Arc Additive Manufacturing (WAAM)

Characterization of 5356 Aluminum Walls Produced by Wire Arc Additive Manufacturing (WAAM)

The effects of building position on surface and fatigue of DED-arc steel components

On the Influence of Linear Energy/Heat Input Coefficient on Hardness and Weld Bead Geometry in Chromium-Rich Stringer GMAW Coatings

Contact Info

Product

Resources

About