Wire arc additive manufacturing of light metals: From experimental investigation to numerical process simulation and microstructural modeling

Kabliman, Evgeniya; Kingsbury, Alex; O’Toole, Patrick; Molotnikov, Andrey; Easton, Mark; Benoit, Michael J.; Horr, A.M.; Drexler, Hugo; Kronsteiner, Johannes; Klein, Thomas; Neubauer, Erich

doi:10.1016/b978-0-323-88664-2.00018-x

Cited by 2 publications

(2 citation statements)

References 94 publications

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“…It focuses on capturing the overall behavior and performance of the materials and components involved in these manufacturing processes. Finite Element Analysis (FEA) is a widely used technique in macroscale modeling for process simulation in metal forming, bending, welding, and casting processes [14]. FEA divides the material into small finite elements, allowing for a detailed analysis of complex geometries, material behavior, and process parameters.…”

Section: Macroscale Modelingmentioning

confidence: 99%

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Bhavana,

Kaushik

et al. 2024

E3S Web Conf.

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Multiscale modeling and simulation offer crucial insights for designing and analyzing metal forming, bending, welding, and casting processes, all of which are vital across automotive, aerospace, and construction industries. This paper overviews multiscale techniques used in these areas. Macroscopically, continuum-based methods like finite element analysis (FEA) model the overall process and its impact on metal materials. FEA reveals deformation, stress distribution, and temperature changes during manufacturing processes. Mesoscale techniques, including crystal plasticity, phase field methods, and cellular automata, focus on microstructural evolution and mechanical properties. They model the behavior of grains and phases within the metal. These models combine macro and mesoscale data for accuracy. This allows for the prediction of grain growth, recrystallization, and phase transformations – critical for optimizing processes, refining component design, and ensuring quality. For example, multiscale modeling successfully captured microstructural evolution during casting (demonstrating ±2% average grain growth deviation) and predicted defect formation in welded joints with high accuracy (demonstrating a 0.95 correlation coefficient with non-destructive testing).

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Section: Macroscale Modelingmentioning

confidence: 99%

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Bhavana,

Kaushik

et al. 2024

E3S Web Conf.

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“…WAAM has gained prominence for its role in mass production as a form of direct energy deposition AM. In recent years, it has experienced substantial growth, owing to its numerous advantages compared to other methods, including higher productivity, the capacity for manufacturing large components, widespread availability of the WAAM process, lower costs, minimal material wastage, and the simplicity of feedstock, among others [1,2].…”

Section: Introductionmentioning

confidence: 99%

Influence of Processes and Process Variables for WAAM – Geometry of Deposited Bead

Li,

Al-Hallis,

Al-Chafey

2024

Advances in Transdisciplinary Engineering

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Wire Arc Additive Manufacturing (WAAM) is developing rapidly in recent years due to its advantages, such as higher productivity, lower cost, acceptable quality, and the availability of advanced welding processes. Cold Metal Transfer (CMT), as the most well-known Gas Metal Arc Welding (GMAW) process, is widely used in WAAM. The uniqueness of CMT lies in minimizing the heat input of the process. However, there is a drawback to the lower heat input, impacting the quality of the geometry of the welding bead, sharp transitions at the weld toe, inclusions, etc., particularly for higher alloyed steel, e.g., tool steel. In this study, two processes were employed: CMT and Pulse Multi Control (PMC). Two types of shielding gases were used, namely 2% CO2 + 98% Ar and 20% CO2 + 80% Ar. Two levels of wire feed speed were selected: high and low levels. A full-fraction factorial experimental matrix was created, and bead-on-plate samples were produced with different GMAW processes, i.e., CMT and PMC. The geometry of the bead-on-plate, including penetration, bead width and height, and toe angle, was evaluated and analyzed. A correlation between the process factors (shielding gas, type of process, and wire feed speed) and the geometry of the bead was analyzed and determined. A protocol is proposed based on the study results for the selection of WAAM processes.

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Wire arc additive manufacturing of light metals: From experimental investigation to numerical process simulation and microstructural modeling

Cited by 2 publications

References 94 publications

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Review of Multiscale Modeling and Simulation Techniques in Metal Forming, Bending, Welding, and Casting Processes for Enhanced Predictive Design and Analysis

Influence of Processes and Process Variables for WAAM – Geometry of Deposited Bead

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