A review of high energy density beam processes for welding and additive manufacturing applications

Patterson, Tate; Hochanadel, Joris E.; Sutton, Scott C.; Panton, B.; Lippold, John C.

doi:10.1007/s40194-021-01116-0

Cited by 33 publications

(8 citation statements)

References 379 publications

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“…Many firms depend on HED beam welding methods including laser beams and electron beams. Patterson et al 68 state that these methods are widely employed in many welding and AM applications containing a wide-ranging of materials Table 2 lists the advantages of HED methods over arc welding procedures.…”

Section: High-energy Density (Hed) Welding-based Additive Manufacturingmentioning

confidence: 99%

Welding-based additive manufacturing processes for fabrication of metallic parts

Rathinasuriyan,

Elumalai,

Bharani Chandar

et al. 2023

Composites and Advanced Materials

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Additive Manufacturing (AM) is modernizing the manufacturing industry by enabling the layer-by-layer deposition process to manufacture objects in nearly any form with minimum material waste. However, components developed utilizing the AM process have dimensional constraints. To address this issue, AM-produced metal materials can be coupled with various welding processes. This article focuses on the foundations, highlighting the distinguishing features, capabilities, and challenges of welding-based AM processes by categorizing them into two major groups; arc welding-based AM like Cold Metal Transfer (CMT), Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), Plasma Arc Welding (PAW), and high-energy density welding based AM like Laser Beam Welding (LBW) and Electron Beam Welding (EBW). The prior study findings of welding-based AM metal components on mechanical characteristics and microstructural characterization have been addressed. This work will aid researchers, academicians, and professional welders since it gathers vital information on welding-based AM processes. Furthermore, current research in the arena of welding-based AM and its future opportunities has been discussed.

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Section: High-energy Density (Hed) Welding-based Additive Manufacturingmentioning

confidence: 99%

Welding-based additive manufacturing processes for fabrication of metallic parts

Rathinasuriyan,

Elumalai,

Bharani Chandar

et al. 2023

Composites and Advanced Materials

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“…Beam welding technologies, such as laser welding [13,14] and electron beam welding [15], have proved satisfactory when welding large thickness parts. However, the high cost of equipment and stringent requirements for the processed surfaces do not allow the use of these methods everywhere.…”

Section: Introductionmentioning

confidence: 99%

Influence of Laser Beam Wobbling Parameters on Microstructure and Properties of 316L Stainless Steel Multi Passed Repaired Parts

et al. 2022

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The results of experimental studies of repair of the supporting structure components made of 316L steel multi-pass laser cladding with filler wire are presented. The influence of the wobbling mode parameters, welding speed, and laser power on the formation of the deposited metal during multi-pass laser cladding with filler wire of 316L steel samples into a narrow slot groove, 6 mm deep and 3 mm wide, are shown. Non-destructive testing, metallographic studies, and mechanical tests of the deposited metal before and after heat treatment (2 h at 450 °C) were carried out. Based on the results of experimental studies, the optimal modes of laser beam wobbling were selected (amplitude—1.3 mm, frequency—100 Hz) at which the formation of a bead of optimal dimensions (height—1672 μm, width—3939 μm, depth of penetration into the substrate—776 μm) was ensured. A laser cladding technology with ESAB OK Autrode 316L filler wire has been developed, which has successfully passed the certification for conformity with the ISO 15614-11 standard. Studies of the chemical elements’ distribution before and after heat treatment showed that, after heat treatment along the grain boundaries, particles with a significantly higher Mo content (5.50%) were found in the sample, presumably precipitated phases. Microstructure studies and microhardness measurements showed that the upper part metal of the third pass, which has a lower microhardness (75% of base metal), higher ferrite content, and differently oriented dendritic austenite, significantly differs from the rest of the cladded metal.

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“…Laser welding has the advantages of high energy density, small heating zone, large weld depth to width ratio, narrow heat affected zone, small deformation, high production efficiency, flexible control, etc. Compared with traditional fusion welding, such as arc welding, laser welding has higher welding speed and can produce high penetration, which significantly improve manufacturing productivity and reduce cost [7]. Compared with electron beam welding, laser welding also has the advantages of no vacuum chamber, in line with the development trend of low energy consumption, short process, high efficiency.…”

Section: Introductionmentioning

confidence: 99%

Innovations in Monitoring, Control and Design of Laser and Laser-Arc Hybrid Welding Processes

Cheng

Ning

et al. 2021

Metals

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With the rapid development of high power laser, laser welding has been widely used in many fields including manufacturing, metallurgy, automobile, biomedicine, electronics, aerospace etc. Because of its outstanding advantages, such as high energy density, small weld size, easy automation. Combining the two heat sources of laser and arc for welding can achieve excellent results due to the synergistic effect. Laser welding is a complicated physical and chemical metallurgical process, involving the laser beam and molten pool, keyholes and materials melting, evaporation and multiple physical process. Process monitoring and quality control are important content of research and development in the field of laser welding, which is the premise to obtain fine weld with high quality. Numerical simulation technology can describe many complex physical phenomena in welding process, which is very important to predict weld forming and quality and clarify the underline mechanism. In this paper, the research progress of process monitoring, quality control and autonomous intelligent design of laser and laser-arc hybrid welding based on numerical simulation were reviewed, and the research hotspots and development trends of laser welding in the future are predicted.

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A review of high energy density beam processes for welding and additive manufacturing applications

Cited by 33 publications

References 379 publications

Welding-based additive manufacturing processes for fabrication of metallic parts

Welding-based additive manufacturing processes for fabrication of metallic parts

Influence of Laser Beam Wobbling Parameters on Microstructure and Properties of 316L Stainless Steel Multi Passed Repaired Parts

Innovations in Monitoring, Control and Design of Laser and Laser-Arc Hybrid Welding Processes

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