3D heat transfer, fluid flow and electromagnetic model for cold metal transfer wire arc additive manufacturing (Cmt-Waam)

Cadiou, S.; Courtois, Mickaël; Carin, Muriel; Berckmans, William; Masson, Philippe

doi:10.1016/j.addma.2020.101541

Cited by 67 publications

(31 citation statements)

References 30 publications

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“…Currently, most researchers use the cold metal transfer (CMT) method [ 11 , 12 , 13 , 14 , 15 , 16 , 17 ]. It allows to separate the molten droplet by mechanical action on the wire, reducing the process temperature.…”

Section: Introductionmentioning

confidence: 99%

Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces

2021

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In this paper, we present the results of a study on droplet transferring with arc space short circuits during wire-arc additive manufacturing (WAAM GMAW). Experiments were conducted on cladding of single beads with variable welding current and voltage parameters. The obtained oscillograms and video recordings were analyzed in order to compare the time parameters of short circuit and arc burning, the average process peak current, as well as the droplets size. Following the experiments conducted, 2.5D objects were built-up to determine the influence of electrode stickout and welding torch travel speed to identify the droplet transferring and formation features. Moreover, the current–voltage characteristics of the arc were investigated with varying WAAM parameters. Process parameters have been determined that make it possible to increase the stability of the formation of the built-up walls, without the use of specialized equipment for forced droplet transfer. In the course of the research, the following conclusions were established: the most stable drop transfer occurs at an arc length of 1.1–1.2 mm, reverse polarity provides the best drop formation result, the stickout of the electrode wire affects the drop transfer process and the quality of the deposited layers. The dependence of the formation of beads on the number of short circuits per unit length is noted.

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Section: Introductionmentioning

confidence: 99%

Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces

2021

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“…Analytical temperature models of DED involve solving of closed form welding heat transfer equations using boundary conditions [16]. Cadiou et al proposed a 3D heat transfer model for wire-arc additive manufacturing process [17] The major limitations of analytical models are their general applicability and failure to address the uncertainties of thermophysical properties. Finite element method (FEM) is a numerical method of modelling of temperature profile.…”

Section: Nomenclature X Imentioning

confidence: 99%

A Hybrid Deep Learning Model for Layer-Wise Melt Pool Temperature Forecasting in Wire-Arc Additive Manufacturing Process

Nalajam

Ramesh

2021

IEEE Access

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Melt pool temperature contains abundant information on metallurgical and mechanical aspects of products produced by additive manufacturing. Forecasting melt pool temperature profile during a process can help in reducing microstructural porosity and residual stresses. Although analytical and numerical models were reported, the performance of these are questionable when applied in real-time. Hence, we developed data-driven models to address this challenge, for continuous forecasting layer-wise melt pool temperature using a hybrid deep learning technique. The melt pool temperature forecasting by the proposed CNN-LSTM model is found to be better than other benchmark models in terms of accuracy and efficiency. The model results have shown that combining CNN and LSTM networks can extract the spatial and temporal information from the melt pool temperature data. Further, the proposed model results are compared with existing statistical and machine learning models. The performance measures of the proposed CNN-LSTM model indicate a greater potential for in-situ monitoring of additive manufacturing process.

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“…In the actual processing process, the laser beam would converge with the powder flow at each processing point according to the planned path; therefore, under the simulation of a moving heat source, the heat effect data could be obtained to improve the convergence point and the radius of the powder flow. It would also make it more efficient with the laser beam cladding to better cooperate with each other [52][53][54][55][56].…”

Section: Simulation Analysis and Stress Analysis Of Hot Cladding Processmentioning

confidence: 99%

Design a New Type of Laser Cladding Nozzle and Thermal Fluid Solid Multi-Field Simulation Analysis

et al. 2021

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Coaxial powder feeding technology in the field of metal additive manufacturing is booming. In this paper, a new laser cladding nozzle with powder feeding channels of inner and outer rings is designed. The nozzle works with a new kind of laser, which is a new heat source with an inner beam and outer beams. The water-cooling channels are simulated in Ansys Workbench. The simulation results present the temperature distribution of the working nozzle and the velocity of the cooling water. The thermal dilation of the nozzle in the working environment is also simulated. The results show that the loop water cooling channel could effectively reduce the high temperature of the nozzle down to about 200 °C. In addition, it could well restrain the thermal deformation of the nozzle lower to 0.35 mm. The equivalent stress of most parts is controlled under 360 MPa. Then, the powder flows of the inner and outer rings of the multiple powder feeding channels are simulated in Ansys Fluent. The convergence effect of the powder flow could be assumed and some significant parameters, such as the velocity, are acquired. The results present that these multiple powder feeding channels could realize the generation and removal of removable supports of workpieces with highly complex shapes and achieve a large processing range and good processing efficiency. The velocity of the powder flow at the outlet is elevated to about 5 mm/s. Then, the thermal cladding states under the new laser heat source of the powder are simulated in Workbench. The temperature of the melting process and the thermal deformation and the equivalent stress/strain of the additive parts are obtained in the emulation. The results emerge that the powder melting range and the ascending temperature of the melting pool are improved with this effect. The greatest temperature of the melting pool is about 2900 °C in the machining process, and the maximum thermal equivalent stress is 1.1407 × 1010 Pa.

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3D heat transfer, fluid flow and electromagnetic model for cold metal transfer wire arc additive manufacturing (Cmt-Waam)

Cited by 67 publications

References 30 publications

Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces

Features of Filler Wire Melting and Transferring in Wire-Arc Additive Manufacturing of Metal Workpieces

A Hybrid Deep Learning Model for Layer-Wise Melt Pool Temperature Forecasting in Wire-Arc Additive Manufacturing Process

Design a New Type of Laser Cladding Nozzle and Thermal Fluid Solid Multi-Field Simulation Analysis

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