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.

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 and arc additively manufactured high-strength steel structures

2021 ◽  
Author(s):  
Johanna Müller ◽  
Jonas Hensel ◽  
Klaus Dilger
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Yield Strength ◽  
High Strength Steel ◽  
Energy Input ◽  
High Strength ◽  
Accelerated Cooling ◽  
Active Cooling ◽  
Wire Arc Additive Manufacturing ◽  
Interpass Temperature

AbstractAdditive manufacturing with steel opens up new possibilities for the construction sector. Especially direct energy deposition processes like DED-arc, also known as wire arc additive manufacturing (WAAM), is capable of manufacturing large structures with a high degree of geometric freedom, which makes the process suitable for the manufacturing of force flow-optimized steel nodes and spaceframes. By the use of high strength steel, the manufacturing times can be reduced since less material needs to be deposited. To keep the advantages of the high strength steel, the effect of thermal cycling during WAAM needs to be understood, since it influences the phase transformation, the resulting microstructure, and hence the mechanical properties of the material. In this study, the influences of energy input, interpass temperature, and cooling rate were investigated by welding thin walled samples. From each sample, microsections were analyzed, and tensile test and Charpy-V specimens were extracted and tested. The specimens with an interpass temperature of 200 °C, low energy input and applied active cooling showed a tensile strength of ~ 860–900 MPa, a yield strength of 700–780 MPa, and an elongation at fracture between 17 and 22%. The results showed the formation of martensite for specimens with high interpass temperatures which led to low yield and high tensile strengths (Rp0.2 = 520–590 MPa, Rm = 780–940 MPa) for the specimens without active cooling. At low interpass temperatures, the increase of the energy input led to a decrease of the tensile and the yield strength while the elongation at fracture as well as the Charpy impact energy increased. The formation of upper bainite due to the higher energy input can be avoided by accelerated cooling while martensite caused by high interpass temperatures need to be counteracted by heat treatment.

Wire arc additive manufacturing of thin-wall low-carbon steel parts: Microstructure and mechanical properties

2020 ◽  
Vol 34 (22n24) ◽  
pp. 2040154
Author(s):  
Van Thao Le ◽  
Tien Long Banh ◽  
Duc Toan Nguyen ◽  
Van Tao Le
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Carbon Steel ◽  
Heat Input ◽  
Low Carbon Steel ◽  
Production Costs ◽  
High Deposition Rate ◽  
Thin Wall ◽  
Low Carbon ◽  
Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) has received much attention for manufacturing metal parts with medium and large dimensions because of its high deposition rate and low production costs. In this study, the effects of the heat input on the microstructure formation of thin-wall low-carbon steel parts built by a WAAM process were addressed. The mechanical properties of built materials were also studied. The results indicate that the heat input significantly influences on the shape of built thin walls, but has slight effects on the microstructure evolution of built materials. The WAAM thin-wall low-carbon steel presents suitable microstructures and good tensile strengths (YS: 320 – 362 MPa, UTS: 429 – 479 MPa) that are adequate with industrial applications.

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 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 Effect of enhanced weld cooling on the mechanical properties of a structural steel with a yield strength of 700 MPa

2020 ◽  
Vol 2 (11) ◽  
Author(s):  
Juhani Laitila ◽  
Lassi Keränen ◽  
Jari Larkiola
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Fatigue Strength ◽  
Impact Toughness ◽  
Yield Strength ◽  
Uniform Elongation ◽  
High Strength ◽  
Low Alloy Steel ◽  
External Cooling ◽  
Welding Processes

AbstractIn this study, we present the effect of enhanced cooling on the mechanical properties of a high-strength low-alloy steel (having a yield strength of 700 MPa) following a single-pass weld process. The properties evaluated in this study include uniform elongation, impact toughness, yield, tensile and fatigue strengths alongside the cooling time of the weld. With the steel used in this study, the enhanced cooling resulted in a weld joint characterized with excellent cross-weld uniform elongation, yield and fatigue strength. The intensified cooling reduced the time it takes for the weld to reach 100 °C by around 190 s. Not only the fusion line of the weld was less pronounced, but also the grain size of the CGHAZ was greatly refined as a result of the enhanced cooling. The results indicate that combining external cooling to the welding processes can be beneficial for the studied high-strength steel.

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 and Arc Additive Manufacturing of High-Strength Al–Zn–Mg Aluminum Alloy

2021 ◽  
Vol 8 ◽  
Author(s):  
Xuewei Fang ◽  
Guopeng Chen ◽  
Jiannan Yang ◽  
Yang Xie ◽  
Ke Huang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Aluminum Alloys ◽  
Electron Backscatter Diffraction ◽  
Vertical Direction ◽  
High Strength ◽  
Thin Wall ◽  
Cold Metal Transfer ◽  
X Ray ◽  
Manufacturing Techniques ◽  
Cold Metal

High-strength 7xxx series aluminum alloys are of great importance for the aerospace industries. However, this type of aluminum alloys has poor processability for most additive manufacturing techniques. In this paper, a newly designed Al–Zn–Mg alloy was used as a feeding wire to fabricate thin wall-shaped samples using the wire and arc additive manufacturing (WAAM) technique. These samples were fabricated based on the cold metal transfer (CMT) process with four different types of arc modes, that is, CMT, CMT-incorporated pulse (CMT + P), CMT-incorporated polarity (CMT + A), CMT-incorporated pulse and polarity (CMT + PA). The optical microscopy, x-ray computed tomography, and scanning electron microscopy equipped with energy-dispersive x-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD) were employed to characterize the microstructure and phase constitution. The results clearly reveal that the porosity varies with the arc modes, and the densest sample with porosity of 0.97% was obtained using the CMT + P mode. The mechanical properties of the fabricated samples are also dependent on the arc modes. The tensile strength and yield strength of the sample manufactured by the CMT + PA arc mode are the highest. In terms of anisotropy, the strength differences in horizontal and vertical direction of the samples made by CMT + PA, CMT + A, and CMT modes are all large, which is mainly ascribed to the pores distributed at the interlayer region.

Sign in / Sign up

Export Citation Format

Share Document