scholarly journals Comparison of Mechanical Properties of Ni-Al-Bronze Alloy Fabricated through Wire Arc Additive Manufacturing with Ni-Al-Bronze Alloy Fabricated through Casting

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1164
Author(s):  
Jisun Kim ◽  
Jaewoong Kim ◽  
Changmin Pyo
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Welding Process ◽  
Wear Test ◽  
Hardness Test ◽  
Longitudinal Direction ◽  
Bronze Alloy ◽  
Cold Metal Transfer ◽  
Wire Arc Additive Manufacturing ◽  
Welding Direction

This study compared the mechanical properties of the NAB (Ni-Al-bronze) material fabricated using wire arc additive manufacturing (WAAM) technology with those of the cast NAB. Using a CMT (cold metal transfer) welding process, this study analyzed the bead shape for six welding conditions, determined an appropriate bead shape, and fabricated a square bulk NAB material using the bead shape. For a mechanical properties comparison, the study obtained two test specimens per welding direction from the fabricated bulk NAB material, and compared those with the cast NAB materials. In the tensile test, the deposited NAB material showed significantly better results than the cast NAB; furthermore, the deposited NAB material showed better performance than the cast NAB material in the Vickers hardness test, impact test and wear test. In addition, the deposited NAB showed anisotropy depending on the welding direction, and showed high tensile strength, hardness and shock absorption in the longitudinal direction of the welding line.

scholarly journals Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Metals ◽  
2018 ◽  
Vol 8 (12) ◽  
pp. 1009 ◽  
Author(s):  
Marcel Graf ◽  
Andre Hälsig ◽  
Kevin Höfer ◽  
Birgit Awiszus ◽  
Peter Mayr
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Additive Manufacturing ◽  
Gas Metal Arc Welding ◽  
Welding Process ◽  
Temperature Fields ◽  
Filler Materials ◽  
Cold Metal Transfer ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

Additive manufacturing processes have been investigated for some years, and are commonly used industrially in the field of plastics for small- and medium-sized series. The use of metallic deposition material has been intensively studied on the laboratory scale, but the numerical prediction is not yet state of the art. This paper examines numerical approaches for predicting temperature fields, distortions, and mechanical properties using the Finite Element (FE) software MSC Marc. For process mapping, the filler materials G4Si1 (1.5130) for steel, and AZ31 for magnesium, were first characterized in terms of thermo-physical and thermo-mechanical properties with process-relevant cast microstructure. These material parameters are necessary for a detailed thermo-mechanical coupled Finite Element Method (FEM). The focus of the investigations was on the numerical analysis of the influence of the wire feed (2.5–5.0 m/min) and the weld path orientation (unidirectional or continuous) on the temperature evolution for multi-layered walls of miscellaneous materials. For the calibration of the numerical model, the real welding experiments were carried out using the gas-metal arc-welding process—cold metal transfer (CMT) technology. A uniform wall geometry can be produced with a continuous welding path, because a more homogeneous temperature distribution results.

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 Effect of Filler Metal Type on Microstructure and Mechanical Properties of Fabricated NiAl Bronze Alloy Using Wire Arc Additive Manufacturing System

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 513
Author(s):  
Jae Won Kim ◽  
Jae-Deuk Kim ◽  
Jooyoung Cheon ◽  
Changwook Ji
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Filler Metal ◽  
Gas Metal Arc Welding ◽  
Metal Wire ◽  
Cold Metal Transfer ◽  
Metal Type ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

This study observed the effect of filler metal type on mechanical properties of NAB (NiAl-bronze) material fabricated using wire arc additive manufacturing (WAAM) technology. The selection of filler metal type is must consider the field condition, mechanical properties required by customers, and economics. This study analyzed the bead shape for representative two kind of filler metal types use to maintenance and fabricated a two-dimensional bulk NAB material. The cold metal transfer (CMT) mode of gas metal arc welding (GMAW) was used. For a comparison of mechanical properties, the study obtained three specimens per welding direction from the fabricated bulk NAB material. In the tensile test, the NAB material deposited using filler metal wire A showed higher tensile strength and lower elongation (approx. +71 MPa yield strength, +107.1 MPa ultimate tensile strength, −12.4% elongation) than that deposited with filler metal wire B. The reason is that, a mixture of tangled fine α platelets and dense lamellar eutectoid α + κIII structure with β´ phases was observed in the wall made with filler metal wire A. On the other hand, the wall made with filler metal wire B was dominated by coarse α phases and lamellar eutectoid α + κIII structure in between.

scholarly journals Characterisation of a High-Performance Al–Zn–Mg–Cu Alloy Designed for Wire Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1610 ◽  
Author(s):  
Paulo J. Morais ◽  
Bianca Gomes ◽  
Pedro Santos ◽  
Manuel Gomes ◽  
Rudolf Gradinger ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Additive Manufacturing ◽  
High Performance ◽  
Mechanical Performance ◽  
Fluorescence Analysis ◽  
Cold Metal Transfer ◽  
Direction Parallel ◽  
X Ray ◽  
Wire Arc Additive Manufacturing

Ever-increasing demands of industrial manufacturing regarding mechanical properties require the development of novel alloys designed towards the respective manufacturing process. Here, we consider wire arc additive manufacturing. To this end, Al alloys with additions of Zn, Mg and Cu have been designed considering the requirements of good mechanical properties and limited hot cracking susceptibility. The samples were produced using the cold metal transfer pulse advanced (CMT-PADV) technique, known for its ability to produce lower porosity parts with smaller grain size. After material simulations to determine the optimal heat treatment, the samples were solution heat treated, quenched and aged to enhance their mechanical performance. Chemical analysis, mechanical properties and microstructure evolution were evaluated using optical light microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, X-ray fluorescence analysis and X-ray radiography, as well as tensile, fatigue and hardness tests. The objective of this research was to evaluate in detail the mechanical properties and microstructure of the newly designed high-performance Al–Zn-based alloy before and after ageing heat treatment. The only defects found in the parts built under optimised conditions were small dispersed porosities, without any visible cracks or lack of fusion. Furthermore, the mechanical properties are superior to those of commercial 7xxx alloys and remarkably independent of the testing direction (parallel or perpendicular to the deposit beads). The presented analyses are very promising regarding additive manufacturing of high-strength aluminium alloys.

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 Wire-arc additive manufacturing of Al-Mg alloy using CMT and PMC technologies

2018 ◽  
Vol 233 ◽  
pp. 00031 ◽  
Author(s):  
Bianca F. Gomes ◽  
Paulo J. Morais ◽  
Vítor Ferreira ◽  
Margarida Pinto ◽  
Luiz H. de Almeida
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Raw Materials ◽  
Industrial Applications ◽  
The Other ◽  
Mg Alloy ◽  
Cold Metal Transfer ◽  
Small Pore ◽  
Wire Arc Additive Manufacturing ◽  
Pore Fraction

Among the several metallic additive manufacturing (MAM) technologies available, the wire-and-arc based ones are very beneficial due to the lower operational costs, higher efficiency use of raw materials, and high deposition rates achieved. The Cold Metal Transfer (CMT) process stands out by the lower heat input compared to the other wire-and-arc based methods. On the other hand, processes such as Pulse Multi Control (PMC) and its variants have not been tested yet in additive manufacturing and for this reason they should be evaluated. Therefore, considering the technologies potential and the need of automotive and aeronautical industry of manufacturing parts of complex and optimized geometry in a faster way, the study of these technologies is very relevant. Thus, the objective of this paper is the additive manufacturing of walls with Al-Mg alloy using CMT, CMT-Pulse, PMC, PMC-Mix, and MIG-Pulse, and the evaluation of the hardness, mechanical strength, and porosity of the manufactured parts aiming future industrial applications. The results showed good mechanical properties, small pore fraction, and geometric uniformity of parts produced with PMC and PMC-Mix. MIG-Pulse and PMC parts presented the smaller pore fraction among the GMAW variants, although no difference was noticed in the mechanical properties of the parts.

scholarly journals Correlations between Microstructure Characteristics and Mechanical Properties in 5183 Aluminium Alloy Fabricated by Wire-Arc Additive Manufacturing with Different Arc Modes

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2075 ◽  
Author(s):  
Xuewei Fang ◽  
Lijuan Zhang ◽  
Guopeng Chen ◽  
Xiaofeng Dang ◽  
Ke Huang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Aluminium Alloy ◽  
Cold Metal Transfer ◽  
Average Pore ◽  
Microstructure Characteristics ◽  
The Difference ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

The effect of arc modes on the microstructure and tensile properties of 5183 aluminium alloy fabricated by cold metal transfer (CMT) processes has been thoroughly investigated. Heat inputs of CMT processes with three arc modes, i.e., CMT, CMT advance (CMT+A), and CMT pulse (CMT+P), were quantified, and their influence on the formation of pores were investigated. The highest tensile strength was found from samples built by the CMT+A process. This agrees well with their smallest average pore sizes. Average tensile strengths of CMT+A arc mode-built samples were 296.9 MPa and 291.8 MPa along the horizontal and vertical directions, respectively. The difference of tensile strength along the horizontal and vertical directions of the CMT+P and CMT samples was mainly caused by the pores at the interfaces between each deposited layer. The successfully built large 5183 aluminium parts by the CMT+A arc mode further proves that this arc mode is a suitable mode for manufacturing of 5183 aluminium alloy.

scholarly journals On the Effect of Heat Input and Interpass Temperature on the Performance of Inconel 625 Alloy Deposited Using Wire Arc Additive Manufacturing–Cold Metal Transfer Process

Metals ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 46
Author(s):  
Chengxun Zhang ◽  
Zhijun Qiu ◽  
Hanliang Zhu ◽  
Zhiyang Wang ◽  
Ondrej Muránsky ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Inconel 625 ◽  
Heat Accumulation ◽  
Cold Metal Transfer ◽  
Inconel 625 Alloy ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature

Relatively high heat input and heat accumulation are treated as critical challenges to affect the qualities and performances of components fabricated by wire arc additive manufacturing (WAAM). In this study, various heat inputs, namely 276, 552 and 828 J/mm, were performed to fabricate three thin-wall Inconel 625 structures by cold metal transfer (CMT)-based WAAM, respectively, and active interpass cooling was conducted to limit heat accumulation. The macrostructure, microstructure and mechanical properties of the produced components by CMT were investigated. It was found that the increased heat input can deteriorate surface roughness, and the size of dendrite arm spacing increases with increasing heat input, thus leading to the deterioration of mechanical properties. Lower heat input and application of active interpass cooling can be an effective method to refine microstructure and reduce anisotropy. This study enhances the understanding of interpass temperature control and the effectiveness of heat inputs for Inconel 625 alloy by WAAM. It also provides a valuable in situ process for microstructure and mechanical properties’ refinement of WAAM-fabricated alloys and the control of heat accumulation for the fabrication of large-sized structures for future practical applications.

scholarly journals Building strategy effect on mechanical properties of high strength low alloy steel in wire + arc additive manufacturing

2020 ◽  
Vol 65 (3) ◽  
pp. 125-136
Author(s):  
Yildiz Suat ◽  
Baris Koc ◽  
Oguzhan Yilmaz
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Yield Strength ◽  
High Strength ◽  
Inert Gas ◽  
High Deposition Rate ◽  
Thin Wall ◽  
Cold Metal Transfer ◽  
Welding Processes ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) which is literally based on continuously fed material deposition type of welding processes such as metal inert gas (MIG), tungsten inert gas (TIG) and plasma welding, is a variant of additive manufacturing technologies. WAAM steps forward with its high deposition rate and low equipment cost as compared to the powder feed and laser/electron beam heated processes among various additive manufacturing processes. In this work, sample parts made of low allow high strength steel (ER120S-G) was additively manufactured via WAAM method using robotic cold metal transfer technology (CMT). The process parameters and building strategies were investigated and correlated with the geometrical, metallurgical and mechanical properties on the produced wall geometries. The results obtained from the thin wall sample parts have showed that with increasing heat input, mechanical properties decreases, since higher heat accumulation and lower cooling rate increases the grain size. The tensile tests results have showed that casting steel (G24Mn6+QT2) mechanical properties which requires 500 MPa yield strength can be compared to with as build WAAM process having 640 MPa yield strength. Tensile strength were fulfilled for S690Q and yield strength is very close to the reference value.

scholarly journals Wire and Arc Additive Manufacturing of Aluminum Components

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 608 ◽  
Author(s):  
Markus Köhler ◽  
Sierk Fiebig ◽  
Jonas Hensel ◽  
Klaus Dilger
Keyword(s):  
Additive Manufacturing ◽  
Process Development ◽  
Complex Geometry ◽  
Welding Process ◽  
Surface Finishing ◽  
Process Conditions ◽  
Efficient Production ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Wire Arc Additive Manufacturing

An increasing demand for flexibility and product integration, combined with reduced product development cycles, leads to continuous development of new manufacturing technologies such as additive manufacturing. Wire and arc additive manufacturing (WAAM) provides promising technology for the near net-shape production of large structures with complex geometry, using cost efficient production resources such as arc welding technology and wire materials. Compared to powder-based additive manufacturing processes, WAAM offers high deposition rates as well as enhanced material utilization. Because of the layer-by-layer built up approach, process conditions such as energy input, arc characteristics, and material composition result in a different processability during the additive manufacturing process. This experimental study aims to describe the effects of the welding process on buildup accuracy and material properties during wire arc additive manufacturing of aluminum structures. Following a process development using pulse cold metal transfer (CMT-P), linear wall samples were manufactured with variations of the filler metal. The samples were analyzed in terms of surface finishing, hardness, and residual stress. Furthermore, mechanical properties were determined in different building directions.

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