Wire Arc Additive Manufacturing (WAAM) for Aluminum-Lithium Alloys: A Review

Rodríguez-González, Paula; Ruiz-Navas, E.M.; Gordo, E.

doi:10.3390/ma16041375

Cited by 13 publications

(11 citation statements)

References 75 publications

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“…However, this technology encounters several challenges [4], [5]. Various issues may arise during manufacturing, including porosity [6], [7], [8], residual stress [9], [10], microstructure concerns [11], and dimensional defects [12], [13].…”

Section: Introductionmentioning

confidence: 99%

A method to qualify image post-processing for thin wall thickness prediction from NIR camera image of aluminum WAAM process

Béraud,

Lombard,

Dellarre

et al. 2024

Preprint

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Wire Arc Additive Manufacturing (WAAM) is a metal arc welding additive process that allows the production of large parts. Managing the quality of produced parts is a key challenge to the adoption of this technology in the industry. A particular case of this is the production of aluminum thin walls and the management of their thicknesses. Literature supports that the use of a near-infrared camera is a good way to monitor the meltpool shape to predict the manufactured thickness. Nevertheless, the post-processing applied to the image has a big influence on the accuracy of the measure. That is why, this article proposes a method to qualify image post-processing for thin wall thickness prediction from near-infrared camera images of aluminum WAAM process. A dataset from the literature is used to evaluate the accuracy of different post-processes. First, a method is proposed to evaluate the accuracy of a given post-process. Secondly, two types of post-processing are presented: post-processing based on conventional image processing and post-processing based on neural networks. Their accuracy is evaluated with the proposed method. The article concludes that the proposed method is adapted to qualify post-processes and that the proposed post-processing based on neural networks gives significant results in terms of accuracy.

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Section: Introductionmentioning

confidence: 99%

A method to qualify image post-processing for thin wall thickness prediction from NIR camera image of aluminum WAAM process

Béraud,

Lombard,

Dellarre

et al. 2024

Preprint

View full text Add to dashboard Cite

show abstract

“…At the same time, it avoids unnecessary heat input through alternating cooling and heating with high current and low voltage. Through the above methods, efficient, spatter-free, and low-heat-input additive manufacturing is achieved [ 1 , 2 , 3 ]. Due to its high additive efficiency and low residual stress characteristics, it has shown a wide range of application prospects in the aerospace and automotive industries.…”

Section: Introductionmentioning

confidence: 99%

Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process

Zhao,

et al. 2024

Materials

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A new heat source combination, consisting of a uniform body heat source and a tilted double ellipsoidal heat source, has been developed for cold metal transfer (CMT) wire-arc additive manufacturing of Mg-Gd-Y-Zn-Zr alloy. Simulations were conducted to analyze the temperature field and stress distribution during the process. The optimal combination of feeding speed and welding speed was found to be 8 m/min and 8 mm/s, respectively, resulting in the lowest thermal accumulation and residual stress. Z-axis residual stress was identified as the main component of residual stress. Electron Backscatter Diffraction (EBSD) testing showed weak texture strength, and Kernel Average Misorientation (KAM) analysis revealed that the 1st layer had the highest residual stress, while the 11th layer had higher residual stress than the 6th layer. Microhardness in the 1st, 11th, and 6th layers varies due to residual stress impacts on dislocation density. Higher residual stress increases dislocation density, raising microhardness in components. The experimental results were highly consistent with the simulated results.

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“…WAAM is a material build-up process whereby metal wires are used as the material feedstock and an electric arc energy source is used for the fusion process [ 14 ]. It is a configuration of directed energy deposition (DED) technology that is both cost-effective and time-efficient [ 15 ].…”

Section: Introductionmentioning

confidence: 99%

Decarburization of Wire-Arc Additively Manufactured ER70S-6 Steel

et al. 2023

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Decarburization is an unwanted carbon-loss phenomenon on the surfaces of a material when they are exposed to oxidizing environments at elevated temperatures. Decarburization of steels after heat treatment has been widely studied and reported. However, up to now, there has not been any systematic study on the decarburization of additively manufactured parts. Wire-arc additive manufacturing (WAAM) is an efficient additive manufacturing process for producing large engineering parts. As the parts produced by WAAM are usually large in size, the use of a vacuum environment to prevent decarburization is not always feasible. Therefore, there is a need to study the decarburization of WAAM-produced parts, especially after the heat treatment processes. This study investigated the decarburization of a WAAM-produced ER70S-6 steel using both the as-printed material and samples heat-treated at different temperatures (800 °C, 850 °C, 900 °C, and 950 °C) for different durations (30 min, 60 min, and 90 min). Furthermore, numerical simulation was carried out using Thermo-Calc computational software to predict the carbon concentration profiles of the steel during the heat treatment processes. Decarburization was found to occur not only in the heat-treated samples but also on the surfaces of the as-printed parts (despite the use of Ar for shielding). The decarburization depth was found to increase with an increase in heat treatment temperature or duration. The part heat-treated at the lowest temperature of 800 °C for merely 30 min was observed to have a large decarburization depth of about 200 μm. For the same heating duration of 30 min, an increase in temperature of 150 °C to 950 °C increased the decarburization depth drastically by 150% to 500 μm. This study serves well to demonstrate the need for further study to control or minimize decarburization for the purpose of ensuring the quality and reliability of additively manufactured engineering components.

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Wire Arc Additive Manufacturing (WAAM) for Aluminum-Lithium Alloys: A Review

Cited by 13 publications

References 75 publications

A method to qualify image post-processing for thin wall thickness prediction from NIR camera image of aluminum WAAM process

A method to qualify image post-processing for thin wall thickness prediction from NIR camera image of aluminum WAAM process

Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process

Decarburization of Wire-Arc Additively Manufactured ER70S-6 Steel

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