scholarly journals Influence of Heat Input on the Formation of Laves Phases and Hot Cracking in Plasma Arc Welding (PAW) Additive Manufacturing of Inconel 718

Metals ◽  
2020 ◽  
Vol 10 (6) ◽  
pp. 771 ◽  
Author(s):  
Teresa Artaza ◽  
Trunal Bhujangrao ◽  
Alfredo Suárez ◽  
Fernando Veiga ◽  
Aitzol Lamikiz
Keyword(s):  
Additive Manufacturing ◽  
Arc Welding ◽  
Inconel 718 ◽  
Fixed Time ◽  
Hot Cracking ◽  
Added Value ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Laves Phases ◽  
Deposition Conditions

Nickel-based alloys have had extensive immersion in the manufacturing world in recent decades, especially in high added value sectors such as the aeronautical sector. Inconel 718 is the most widespread in terms of implantation. Therefore, the interest in adapting the manufacture of this material to additive manufacturing technologies is a significant objective within the scientific community. Among these technologies for the manufacture of parts by material deposition, plasma arc welding (PAW) has advantages derived from its simplicity for automation and integration on the work floor with high deposition ratios. These characteristics make it very economically appetizing. However, given the tendency of this material to form precipitates in its microstructure, its manufacturing by additive methods is very challenging. In this article, three deposition conditions are analyzed in which the energy and deposition ratio used are varied, and two cooling strategies are studied. The interpass cooling strategy (ICS) in which a fixed time is expected between passes and controlled overlay strategy (COS) in which the temperature at which the next welding pass starts is controlled. This COS strategy turns out to be advantageous from the point of view of the manufacturing time, but the deposition conditions must be correctly defined to avoid the formation of Laves phases and hot cracking in the final workpiece.

scholarly journals Self-adaptive control system for additive manufacturing using double electrode micro plasma arc welding

2020 ◽  
Author(s):  
Nan Li ◽  
Ding Fan ◽  
Jiankang Huang ◽  
Shurong Yu ◽  
Wen Yuan ◽  
...  
Keyword(s):  
Control System ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Deposition Process ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Metal Parts ◽  
Double Electrode ◽  
Micro Plasma Arc Welding ◽  
Wire Feed

Abstract Wire arc additive manufacturing (WAAM) has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost. However, in the process of automatically manufacturing the high-quality metal parts by WAAM, several problems about the heat build-up, the deposit-path optimization, and the stability of the process parameters need to be well addressed. To overcome these issues, a new WAAM method based on the double electrode micro plasma arc welding (DE-MPAW) was designed. The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically. The effects between the parameters, wire feed rate and torch stand-off distance, in the process of WAAM were investigated experimentally. In addition, a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance . Finally, a series of tests were performed to evaluate the control system’s performance . The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system. Further, the deposition paths about the metal part’s layer heights in WAAM are simplified. Finally, the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

scholarly journals Measurement and Simulation of Low Carbon Steel Alloy Deposit Temperature in plasma Arc Welding Additive Manufacturing

2014 ◽  
Vol 2 (6) ◽  
pp. 113-127
Author(s):  
Abdullah Alhuzaim ◽  
R. Bruce Madigan
Keyword(s):  
Grain Size ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Arc Welding ◽  
Low Carbon Steel ◽  
Heat Removal ◽  
Wait Time ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Low Carbon

Additive manufacturing has the potential to produce near-net shape parts directly from weld metal. Prior work has proved that it is possible to directly manufacture components with complex geometric features and with good productivity. However, under high productivity conditions, deposit temperature increases to a level that it is no longer possible to develop appropriate deposit microstructure and therefore mechanical properties. In this study, Plasma Arc welding was used to produce experimental deposits of 1018 low carbon steel under various conditions. An analytical heat flow model was developed to study the influence of interlayer wait time on deposit temperature and therefore grain size and hardness. The results of the model indicated that as wall height increased, the rate of deposit heat removal by conduction to the substrate decreased leading to a higher preheat temperature after a fixed interlayer wait time causing grain size to increase as wall height increased. However, the model results also show that as wall height increased, the deposit surface area from which heat energy is lost via convection and radiation increased. The model also demonstrated that the use of a means of forced convection to rapidly remove heat from the deposit could be an effective way to boost productivity and maintain smaller grain size and therefore higher hardness and strength in the deposit.

scholarly journals Self-Adaptive Control System for Additive Manufacturing Using Double Electrode Micro Plasma Arc Welding

2021 ◽  
Vol 34 (1) ◽  
Author(s):  
Nan Li ◽  
Ding Fan ◽  
Jiankang Huang ◽  
Shurong Yu ◽  
Wen Yuan ◽  
...  
Keyword(s):  
Control System ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Deposition Process ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Metal Parts ◽  
Double Electrode ◽  
Micro Plasma Arc Welding ◽  
Wire Feed

AbstractWire arc additive manufacturing (WAAM) has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost. However, in the process of automatically manufacturing the high-quality metal parts by WAAM, several problems about the heat build-up, the deposit-path optimization, and the stability of the process parameters need to be well addressed. To overcome these issues, a new WAAM method based on the double electrode micro plasma arc welding (DE-MPAW) was designed. The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically. The effects between the parameters, wire feed rate and torch stand-off distance, in the process of WAAM were investigated experimentally. In addition, a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance. Finally, a series of tests were performed to evaluate the control system’s performance. The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system. Further, the deposition paths about the metal part’s layer heights in WAAM are simplified. Finally, the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

scholarly journals Self-adaptive control system for additive manufacturing using double electrode micro plasma arc welding

2021 ◽  
Author(s):  
Nan Li ◽  
Ding Fan ◽  
Jiankang Huang ◽  
Shurong Yu ◽  
Wen Yuan ◽  
...  
Keyword(s):  
Control System ◽  
Additive Manufacturing ◽  
Arc Welding ◽  
Deposition Process ◽  
Plasma Arc Welding ◽  
Plasma Arc ◽  
Metal Parts ◽  
Double Electrode ◽  
Micro Plasma Arc Welding ◽  
Wire Feed

Abstract Wire arc additive manufacturing (WAAM) has been investigated to deposit large-scale metal parts due to its high deposition efficiency and low material cost. However, in the process of automatically manufacturing the high-quality metal parts by WAAM, several problems about the heat build-up, the deposit-path optimization, and the stability of the process parameters need to be well addressed. To overcome these issues, a new WAAM method based on the double electrode micro plasma arc welding (DE-MPAW) was designed. The circuit principles of different metal-transfer models in the DE-MPAW deposition process were analyzed theoretically. The effects between the parameters, wire feed rate and torch stand-off distance, in the process of WAAM were investigated experimentally. In addition, a real-time DE-MPAW control system was developed to optimize and stabilize the deposition process by self-adaptively changing the wire feed rate and torch stand-off distance. Finally, a series of tests were performed to evaluate the control system’s performance. The results show that the capability against interferences in the process of WAAM has been enhanced by this self-adaptive adjustment system. Further, the deposition paths about the metal part’s layer heights in WAAM are simplified. Finally, the appearance of the WAAM-deposited metal layers is also improved with the use of the control system.

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