Concept and validation of an active cooling technique to mitigate heat accumulation in WAAM

Silva, Leandro João da; Souza, Danielle Monteiro; Araújo, Douglas Bezerra de; Reis, Ruham Pablo; Scotti, Américo

doi:10.1007/s00170-020-05201-4

Cited by 102 publications

(42 citation statements)

References 26 publications

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“…Owing to longer cooling times (t 8/5 ), the proposed high-pressure air cooling allows for fewer changes in microstructure and hardness. On the other hand, shorter production times can be obtained if water bath cooling is used [13].…”

Section: The Cooling Systemmentioning

confidence: 99%

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WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Kozamernik

Bračun

Klobčar

2020

Int J Adv Manuf Technol

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In an attempt to find a solution similar to the FDM 3D printers which would allow cost-effective and reliable additive manufacturing of metal components, this paper proposes a three-axis WAAM system capable of reliably printing small, near-net-shape metal objects. The system consists of gas metal arc (GMA) process equipment, a three-axis CNC positioning system, the interpass temperature control and forced cooling of the base plate and the deposit. The main challenge addressed is the minimisation of shape distortions caused by excessive heat accumulation when printing small objects. The interpass temperature control uses an IR pyrometer to remotely measure the last deposited layer and a control system to keep the interpass temperature below the predefined value by stopping the deposition after each layer in order to allow the deposit to cool. This results in a stable and more repeatable shape of the deposit, even when the heat transfer conditions are changing during the build-up process. The combination of adaptive interlayer dwell time and forced cooling significantly improves system productivity. Open-source NC control and path generation software is used, which enables fast and easy creation of the control code. Different control methods are evaluated through the printing of simple walls, and the printing accuracy is evaluated by printing small shell objects. As the results show, the interpass temperature control allows small objects to be printed at near-net shape with a deviation of 2%, which means that successful printing of 3D shapes can be achieved without trial and error approach.

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Section: The Cooling Systemmentioning

confidence: 99%

“…Other thermal management approaches have also been investigated. Da Silva et al [13] examined the WAAM of aluminium alloy Al5Mg using the CMT process. The object was printed inside a work tank filled with water and the water level rose when the metal layers were deposited.…”

Section: Introductionmentioning

confidence: 99%

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Kozamernik

Bračun

Klobčar

2020

Int J Adv Manuf Technol

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“…Therefore, investigations on energy reduced welding regimes were carried out [19,20]. Moreover, cooling strategies were developed to reduce interlayer temperatures and enhance processing times [21,22]. However, the described methods of energy reduction are commonly coupled to specific hardware such as welding power sources with energy reduced processes or additional equipment, e.g., fluid bath, cooling clamps, etc.…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

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Wire arc additive manufacturing (WAAM) by gas metal arc welding (GMAW) is a suitable option for the production of large volume metal parts. The main challenge is the high and periodic heat input of the arc on the generated layers, which directly affects geometrical features of the layers such as height and width as well as metallurgical properties such as grain size, solidification or material hardness. Therefore, processing with reduced energy input is necessary. This can be implemented with short arc welding regimes and respectively energy reduced welding processes. A highly efficient strategy for further energy reduction is the adjustment of contact tube to work piece distance (CTWD) during the welding process. Based on the current controlled GMAW process an increase of CTWD leads to a reduction of the welding current due to increased resistivity in the extended electrode and constant voltage of the power source. This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel. Thereby, an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.

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“…Various types of cooling media have been adopted for active cooling in AM. [ 5,16–20 ] However, the effect of active cooling varies with specific process implementations. For instance, different layers in a sample fabricated with a water bath as the cooling medium have different cooling rates according to the water level.…”

Section: Introductionmentioning

confidence: 99%

“…To improve the water‐bath method, Silva et al adopted a changing level to maintain the effect of water and demonstrated that the latter layers had similar thermal cycles. [ 18 ]…”

Section: Introductionmentioning

confidence: 99%

Effect of Modified Water‐Bath Method on Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Low‐Carbon Low‐Alloy Steel

Luo

You

et al. 2021

steel research int.

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Of late, wire arc additive manufacturing (WAAM) is extensively used in the aerospace and automotive fields to produce large complex metallic components. The water‐bath method is applied for active cooling to address the heat accumulation problem in WAAM. Herein, the modified water‐bath method with a changing level is used to realize different phase transformations, and the microstructure and mechanical properties of the sample are investigated. Heat accumulation in the sample is eliminated using the modified water‐bath method. Furthermore, the microstructure of the fabricated sample shows a mixture of polygonal ferrite (PF), upper bainite (UB), and lath bainite (LB). Layer bands are formed in the entire sample, except in the final layer, and equiaxed ferrite (EF) and an increased fraction of PF appear in these zones. The microhardness and tensile property are enhanced due to the fine LB. The considerable difference in the microhardness between LB and PF causes an obvious wave of hardness, and the tensile property along the horizontal direction is better than the vertical. This study is expected to help broaden the application of the water bath in the microstructure control.

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Concept and validation of an active cooling technique to mitigate heat accumulation in WAAM

Cited by 102 publications

References 26 publications

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Effect of Modified Water‐Bath Method on Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Low‐Carbon Low‐Alloy Steel

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