Improvement in Geometrical Accuracy and Mechanical Property for Arc-Based Additive Manufacturing Using Metamorphic Rolling Mechanism

2016 ◽  
Vol 138 (11) ◽  
Author(s):  
Yang Xie ◽  
Haiou Zhang ◽  
Fei Zhou
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Vertical Direction ◽  
Shrinkage Porosity ◽  
Hybrid Manufacturing ◽  
High Deposition Rate ◽  
Geometrical Accuracy ◽  
Rolling Mechanism

Additive manufacturing (AM), or 3D printing, is drawing considerable contemporary interest due to its characteristics of high material utilization, great flexibility in product design, and inherent moldless process. Arc-based AM (AAM) is a promising AM method with high deposition rate and favorable buildup quality. Components made by AAM are fabricated through superimposed weld beads deposited from metal wire. Unlike laser-based additive manufacturing, AAM is more difficult to control. Because of the large energy input of the energy source and the liquidity of the melting metal material, bottleneck problems like shrinkage porosity, cracking, residual stresses, and deformation occur. Resultant poor geometrical accuracy and mechanical property keep AAM from industrial application. Especially in the aerospace industry, structural and mechanical property specifications are stringent and critical. This paper presents a novel hybrid manufacturing method by using hot-rolling process to assist the arc welding to solve the above problems. Initially, a miniature metamorphic rolling mechanism (MRM) was developed using metamorphic mechanism theory. Configuration and topology of the MRM can change according to the feature of the components to roll the top and lateral surfaces of the bead. Subsequently, three single-pass multilayer walls were built, respectively, for comparison. The rolled results show significant improvement in geometrical accuracy of the built features. Tensile test results demonstrate improvement in mechanical properties. The improved mechanical properties of rolled specimens are superior to wrought material in travel direction. Microstructure comparisons indicate columnar grains observed in vertical direction and fusion zones were suppressed. Eventually, fabrication of a large-scale aerospace component validates the feasibility of industry application for the hybrid manufacturing technology.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

scholarly journals Mechanical properties of wire arc additive manufactured carbon steel cylindrical component made by gas metal arc welding process

2021 ◽  
Vol 30 (1) ◽  
pp. 188-198
Author(s):  
Bellamkonda Prasanna Nagasai ◽  
Sudersanan Malarvizhi ◽  
Visvalingam Balasubramanian
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Large Scale ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Vertical Direction ◽  
Low Carbon ◽  
Cylindrical Component ◽  
Wire Arc Additive Manufacturing

Abstract Wire arc additive manufacturing (WAAM), a welding-based additive manufacturing (AM) method, is a hot topic of research since it allows for the cost-effective fabrication of large-scale metal components at relatively high deposition rates. In the present study, the cylindrical component of low carbon steel (ER70S-6) was built by WAAM technique, using a GMAW torch that was translated by an automated three-axis motion system using a rotation table. The mechanical properties of the component were evaluated by extracting tensile, impact toughness and hardness specimens from the two regions of the building up (vertical) direction. It is found that the tensile properties of the built material exhibited anisotropic characteristics. The yield strength and ultimate tensile strength varied from 333 to 350 MPa and from 429 to 446 MPa, respectively, (less than 5 % variation).

Wire Arc Additive Manufacturing (WAAM): Reviewing Technology, Mechanical Properties, Applications and Challenges

2020 ◽  
Author(s):  
Moosa Zahid ◽  
Khizar Hai ◽  
Mujtaba Khan ◽  
Ahmed Shekha ◽  
Salman Pervaiz ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Manufacturing Sector ◽  
Economic Feasibility ◽  
Inert Gas ◽  
High Deposition Rate ◽  
Design Concepts ◽  
Industrial Sectors ◽  
Wire Arc Additive Manufacturing

Abstract Because of the flexible nature of 3D printing and additive manufacturing technology, manufacturing sector has been revolutionized. There is a possibility to manufacture different intricate geometrics that cannot be produced through conventional processes previously. The conventional design concepts such as design for manufacture (DFM) and design for assembly (DFA) have been modified and simplified. Wire arc additive manufacturing (WAAM) has emerged as one of the leading additive manufacturing (AM) processes due to its high deposition rate and economic feasibility. A lot of progress has been made to understand and improve this process and the mechanical properties associated with the fabricated parts. It is specifically cheaper to print large-scale metallic components using WAAM. This paper gives a thorough review of the work that has been done on WAAM by comparing different technological variants of WAAM, which include Metal Inert Gas (MIG), Tungsten Inert Gas (TIG) and Plasma Arc Welding (PAW). The study also discusses the mechanical properties of the fabricated components using different metals, the defects and challenges the process faces today and how they can be reduced. In the end the study also provides overview of WAAM applications in some of the industrial sectors such as construction, automotive, and structural etc.

scholarly journals High-Temperature Mechanical Properties of IN718 Alloy: Comparison of Additive Manufactured and Wrought Samples

Crystals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 689
Author(s):  
Trunal Bhujangrao ◽  
Fernando Veiga ◽  
Alfredo Suárez ◽  
Edurne Iriondo ◽  
Franck Girot Mata
Keyword(s):  
Mechanical Properties ◽  
High Temperature ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Low Cost ◽  
Tensile Tests ◽  
High Deposition Rate ◽  
High Temperature Mechanical Properties ◽  
Manufacturing Techniques ◽  
Wire Arc Additive Manufacturing

Wire Arc Additive Manufacturing (WAAM) is one of the most appropriate additive manufacturing techniques for producing large-scale metal components with a high deposition rate and low cost. Recently, the manufacture of nickel-based alloy (IN718) using WAAM technology has received increased attention due to its wide application in industry. However, insufficient information is available on the mechanical properties of WAAM IN718 alloy, for example in high-temperature testing. In this paper, the mechanical properties of IN718 specimens manufactured by the WAAM technique have been investigated by tensile tests and hardness measurements. The specific comparison is also made with the wrought IN718 alloy, while the microstructure was assessed by scanning electron microscopy and X-ray diffraction analysis. Fractographic studies were carried out on the specimens to understand the fracture behavior. It was shown that the yield strength and hardness of WAAM IN718 alloy is higher than that of the wrought alloy IN718, while the ultimate tensile strength of the WAAM alloys is difficult to assess at lower temperatures. The microstructure analysis shows the presence of precipitates (laves phase) in WAAM IN718 alloy. Finally, the effect of precipitation on the mechanical properties of the WAAM IN718 alloy was discussed in detail.

A Literature Review on the Wire and Arc Additive Manufacturing—Welding Systems and Software

2021 ◽  
Vol 13 (8) ◽  
pp. 1391-1400
Author(s):  
Zidong Lin ◽  
Pengfei Liu ◽  
Xinghua Yu
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Tool Path ◽  
Future Research ◽  
High Deposition Rate ◽  
Efficient Technology ◽  
The Past ◽  
Material Efficiency ◽  
Systems Software ◽  
Design Generation

Wire and arc additive manufacturing (WAAM) is considered to be an economic and efficient technology that is suitable to produce large-scale and ultra-large-scale metallic components. In the past two decades, it has been widely investigated in different fields, such as aerospace, automotive and marine industries. Due to its relatively high deposition rate, material efficiency, and shortened lead time compared to other powder-based additive manufacturing (AM) techniques, wire and arc additive manufacturing (WAAM) has been significantly noticed and adopted by both academic researchers and industrial engineers. In order to summarize the development achievements of wire and arc additive manufacturing (WAAM) in the past few years and outlook the development direction in the coming days, this paper provides an overview of 3D metallic printing by applying it as a deposition method. The review mainly focuses on the current welding systems, software for tool path design, generation, and planning used in wire and arc additive manufacturing (WAAM). In the end, the state of the art and future research on wire and arc additive manufacturing (WAAM) have been prospected.

Feasibility and Characterization of Large-Scale Additive Manufacturing With Long Fiber Reinforced Composites

2020 ◽  
Author(s):  
Aditya R. Thakur ◽  
Ming C. Leu ◽  
Xiangyang Dong
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fiber ◽  
Carbon Fibers ◽  
Large Scale ◽  
Flexural Modulus ◽  
High Deposition Rate ◽  
Reinforced Composites ◽  
Fiber Reinforced ◽  
Continuous Fiber ◽  
Long Carbon Fibers

Abstract A new additive manufacturing (AM) approach to fabricate long fiber reinforced composites (LFRC) was proposed in this study. A high deposition rate was achieved by the implementation of a single-screw extruder, which directly used thermoplastic pellets and continuous fiber tows as feedstock materials. Thus, the proposed method was also used as a large-scale additive manufacturing (LSAM) method for printing large-volume components. Using polylactic acid (PLA) pellets and continuous carbon fiber tows, the feasibility of the proposed AM method was investigated through printing LFRC samples and further demonstrated by fabricating large-volume components with complex geometries. The printed LFRC samples were compared with pure thermoplastic and continuous fiber reinforced composite (CFRC) counterparts via mechanical tests and microstructural analyses. With comparable flexural modulus, the flexural strength of the LFRC samples was slightly lower than that of the CFRC samples. An average improvement of 28% in flexural strength and 50% in flexural modulus were achieved compared to those of pure PLA parts, respectively. Discontinuous long carbon fibers, with an average fiber length of 20.1 mm, were successfully incorporated into the printed LFRC samples. The carbon fiber orientation, distribution of carbon fiber length, and dispersion of carbon fiber as well as porosity were further studied. The carbon fibers were highly oriented along the printing direction with a relatively uniformly distributed fiber reinforcement across the LFRC cross section. With high deposition rate (up to 0.8 kg/hr) and low material costs (< $10/kg), this study demonstrated the potentials of the proposed printing method in LSAM of high strength polymer composites reinforced with long carbon fibers.

scholarly journals Wire Arc Additive Manufacturing (WAAM) of Aluminum Alloy AlMg5Mn with Energy-Reduced Gas Metal Arc Welding (GMAW)

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2671 ◽  
Author(s):  
Maximilian Gierth ◽  
Philipp Henckell ◽  
Yarop Ali ◽  
Jonas Scholl ◽  
Jean Pierre Bergmann
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Energy Input ◽  
Large Scale ◽  
Unit Length ◽  
Gas Metal Arc Welding ◽  
Cold Metal Transfer ◽  
Metal Arc Welding ◽  
Wire Arc Additive Manufacturing

Large-scale aluminum parts are used in aerospace and automotive industries, due to excellent strength, light weight, and the good corrosion resistance of the material. Additive manufacturing processes enable both cost and time savings in the context of component manufacturing. Thereby, wire arc additive manufacturing (WAAM) is particularly suitable for the production of large volume parts due to deposition rates in the range of kilograms per hour. Challenges during the manufacturing process of aluminum alloys, such as porosity or poor mechanical properties, can be overcome by using arc technologies with adaptable energy input. In this study, WAAM of AlMg5Mn alloy was systematically investigated by using the gas metal arc welding (GMAW) process. Herein, correlations between the energy input and the resulting temperature–time-regimes show the effect on resulting microstructure, weld seam irregularities and the mechanical properties of additively manufactured aluminum parts. Therefore, multilayer walls were built layer wise using the cold metal transfer (CMT) process including conventional CMT, CMT advanced and CMT pulse advanced arc modes. These processing strategies were analyzed by means of energy input, whereby the geometrical features of the layers could be controlled as well as the porosity to area portion to below 1% in the WAAM parts. Furthermore, the investigations show the that mechanical properties like tensile strength and material hardness can be adapted throughout the energy input per unit length significantly.

scholarly journals Finite Element Modeling and Validation of Metal Deposition in Wire Arc Additive Manufacturing

2021 ◽  
pp. 61-66
Author(s):  
Akram Chergui ◽  
Nicolas Beraud ◽  
Frédéric Vignat ◽  
François Villeneuve
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Large Scale ◽  
Low Cost ◽  
Source Model ◽  
Metal Deposition ◽  
High Deposition Rate ◽  
Element Technique ◽  
Metallic Parts ◽  
Wire Arc Additive Manufacturing

AbstractWire arc additive manufacturing allows the production of metallic parts by depositing beads of weld metal using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this work, a new finite element technique is proposed in order to model metal deposition in WAAM process. This technique allows to gradually construct the mesh representing the deposited regions along the deposition path. The heat source model proposed by Goldak is adapted and combined with the proposed metal deposition technique taking into account the energy distribution between filler material and the molten pool. The effectiveness of the proposed method is validated by series of experiments, of which an example is detailed in this paper.

scholarly journals Microstructure and Properties of ER50-6 Steel Fabricated by Wire Arc Additive Manufacturing

Scanning ◽  
2021 ◽  
Vol 2021 ◽  
pp. 1-8
Author(s):  
Qingxian Hu ◽  
Junyan Miao ◽  
Xiaoli Wang ◽  
Chengtao Li ◽  
Kewei Fang
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Vertical Direction ◽  
Granular Pearlite ◽  
Average Hardness ◽  
Corrosion Behaviors ◽  
Deterioration Effect ◽  
Mechanical Properties And Corrosion ◽  
Equiaxed Grains ◽  
Wire Arc Additive Manufacturing

In this paper, ER50-6 steel was fabricated by wire arc additive manufacturing (WAAM) with an A-W GTAW system. The microstructure, mechanical properties, and corrosion behaviors of ER50-6 steel by WAAM were studied. The results showed that, with the GMAW current increased, from the bottom to the top of the sample, the microstructure was fine ferrite and granular pearlite, ferrite equiaxed grains with fine grains at grain boundaries, and columnar ferrite, respectively. The average hardness in the vertical direction of samples 1# and 2# was 146 and 153 HV, respectively. The hardness of sample 2# increased because of the refinement of grain. The pores in the sample increased as the bypass current increased. The higher bypass current also has a deterioration effect on the corrosion behavior of ER50-6 steel.

Sign in / Sign up

Export Citation Format

Share Document