Analysis of material property models on WAAM distortion using nonlinear numerical computation and experimental verification with P-GMAW

Manurung, Yupiter Harangan Prasada; Prajadhiana, Keval P.; Adenan, Mohd Shahriman; Awiszus, Birgit; Graf, Marcel; André, Hugo

doi:10.1007/s43452-021-00189-4

Cited by 12 publications

(3 citation statements)

References 34 publications

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“…Material structure and defects created during additive manufacturing contribute to the wide range of mechanical properties of these parts, thus limiting their use for critical applications. Wire + arc additive manufacture (WAAM) is beneficial for the manufacturing of metal components with large sizes because of its low cost and high deposition rate [8][9][10]. The metal wire is melted by an electric arc and the components can be deposited layer-by-layer based on its 3D model.…”

Section: Introductionmentioning

confidence: 99%

Comparative analysis of cold and warm rolling on tensile properties and microstructure of additive manufactured Inconel 718

Zhang

Gong

et al. 2022

Archiv.Civ.Mech.Eng

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Despite the high efficiency and low cost of wire + arc additive manufacture (WAAM), the epitaxial grown columnar dendrites of WAAM deposited Inconel 718 cause inferior properties and severe anisotropy compared to the wrought components. Fundamental studies on the influence of one-pass cold and warm rolling on hardness and microstructure were investigated. Then the interpass cold and warm rolling on tensile properties were also analyzed. The results show that the one-pass rolling increases the hardness and displays a heterogeneous hardness distribution compared to the as-deposited material, and the warm rolling exhibits a larger and deeper strain compared to cold rolling. The columnar dendrites gradually change to cell dendrites under the rolling process and then change to equiaxed grains with the subsequent new layer deposition.The average grain size is 16.8 μm and 23.5 μm for the warm and cold rolling, respectively. The strongly textured columnar dendrites with preferred <001> orientation transform to equiaxed grains with random orientation after rolling process. The grain refinement contributes to the dispersive distributed strengthening phases and the increase in its fraction with heat treatment. The as-deposited samples show superior tensile properties compared to the cast material but inferior compared to the wrought components, while the warm-rolled samples show superior tensile properties to wrought material. Isotropic tensile properties are obtained in warm rolling compared to cold rolling. The rolling process and heat treatment both decrease the elongation and lead to a transgranular ductile fracture mode. Finally, the rolling induced strengthening mechanism was discussed.

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Section: Introductionmentioning

confidence: 99%

Comparative analysis of cold and warm rolling on tensile properties and microstructure of additive manufactured Inconel 718

Zhang

Gong

et al. 2022

Archiv.Civ.Mech.Eng

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“…The substrate of SS304 stainless steel was analysed in terms of substrate deformation and plastic strain induced by 25 layers of WAAM-deposited SS316L. The numerical computation procedure and experimental investigation were based on previous studies conducted by the authors with some improvements of parameters leading to the betterment of the result (Prajadhiana et al , 2021; Manurung et al , 2021; Guo et al , 2019).…”

Section: Introductionmentioning

confidence: 99%

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Prajadhiana

Manurung

Bauer

et al. 2021

RPJ

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Purpose This paper aims to numerical and experimental analysis on substrate deformation and plastic strain induced by wire arc additive manufacturing. Design/methodology/approach The component has the form of a hollow, rectangular thin wall consisting of 25 deposition layers of SS316L on an SS304 substrate plate. Thermo-mechanical finite element analysis was applied with Goldak’s double-ellipsoidal heat-source model and a non-linear isotropic hardening rule based on von Mises’ yield criterion. The layer deposition was modelled using simplified geometry to minimize overall pre-processing work and computational time. Findings A new material modelling of SS316L was obtained from the chemical composition of the evolved component characterized by scanning electron microscope/energy dispersive X-ray and further generated by an advanced material-modelling software JMatPro. In defining heat-transfer coefficients, transient thermometric analysis was first performed in the bead and on the substrate, which was followed by an adjustment of the heat-transfer coefficients to reflect the actual temperature distribution. Based on the adjusted model and boundary conditions, sensitivity analysis was conducted prior to the ultimate simulation of substrate deformation and equivalent plastic strain. Furthermore, this simulation was verified by conducting a series of automated wire + arc additive manufacturing tests using robotic gas Metal arc welding with distortion measured by coordinate-measurement machine and equivalent plastic strain measured by optical three-dimensional-metrology measurements (Gesellschaft für Optische Messtechnik). Originality/value It can be concluded that a proper numerical computation using the adjusted model and property-evolved material exhibits a similar trend with acceptable agreement compared to the experiment by yielding an error percentage up to 30% for deformation and up to 21% for equivalent plastic strain at each individual measurement point.

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“…The basic procedures of VM for WAAM research is shown in Fig. 1 as proposed by author's previous research [23].…”

Section: Introductionmentioning

confidence: 99%

Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification

Prajadhiana¹,

Manurung²,

Bauer³

et al. 2021

JAEDS

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This paper deals with a principal development of virtual manufacturing (VM) procedure to predict substrate distortion induced by Wire Arc Additive Manufacturing (WAAM) process. In this procedure, a hollow shape is designed in a thin-walled form made of stainless steel. The procedure starts with geometrical modelling of WAAM component consisting of twenty-five deposited layers with austenitic stainless-steel wire SS316L as feedstock and SS304 as substrate material. The hollow shape is modelled based on simplified rectangular mesh geometry with identical specimen dimensions during the experiment. Material model to be defined can be retrieved directly from a database or by conducting a basic experiment to obtain the evolution of material composition, characterized using Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray (EDX) analysis, and generated using advanced modelling software JMATPRO for creating new properties including the flow curves. Further, a coupled thermomechanical solution is adopted, including phase-change phenomena defined in latent heat, whereby temperature history due to successive layer deposition is simulated by coupling the heat transfer and mechanical analysis. Transient thermal distribution is calibrated from an experiment obtained from thermocouple analysis at two reference measurement locations. New heat transfer coefficients are to be adjusted to reflect actual temperature change. As the following procedure prior to simulation execution, a sensitivity analysis was conducted to find the optimal number of elements or mesh size towards temperature distribution. The last procedure executes the thermomechanical numerical simulation and analysis the post-processing results. Based on all aspects in VM procedures and boundary conditions, WAAM distortion is verified using a robotic welding system equipped with a pulsed power source. The experimental substrate distortion is measured at various points before and after the process. It can be concluded based on the adjusted model and experimental verification that using nonlinear numerical computation, the prediction of substrate distortion with evolved material property of component yields far better result which has the relative error less than 11% in a comparison to database material which has 22%, almost doubled the inaccuracy.

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Analysis of material property models on WAAM distortion using nonlinear numerical computation and experimental verification with P-GMAW

Cited by 12 publications

References 34 publications

Comparative analysis of cold and warm rolling on tensile properties and microstructure of additive manufactured Inconel 718

Comparative analysis of cold and warm rolling on tensile properties and microstructure of additive manufactured Inconel 718

Experimental verification of computational and sensitivity analysis on substrate deformation and plastic strain induced by hollow thin-walled WAAM structure

Methodical procedure of virtual manufacturing for analysing WAAM distortion along with experimental verification

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