Determination of Process Parameter for Twin-Wire Weld-Deposition Based Additive Manufacturing

Abstract

Various energy sources are available for sintering and/or depositing the material in additive manufacturing for metallic objects. These can be mainly categorized as laser based, electron beam based and arc based. While laser and electron offer better surface finish, it is possible to achieve high deposition rates in arc based weld-deposition. The inferior surface finish can be compensated by going for a hybrid system, combining deposition and machining. Twin-wire based weld-deposition, used in the present work, makes it possible to even realize functionally gradient material matrix; the use of two different filler materials into a single weld-pool makes this possible. Wire speed, torch speed and filler material are important factors that effect the composition of the deposited volume. Determination of the operating range and effect of these process parameters therefore is important to control the properties of the weld-deposited gradient objects. The current work presents the material composition of two filler materials ER70S6 and ER110SG with different wire speed and torch speed. Deposited material elemental compositions were analyzed using ED-XRF machine.

Hybridization in wire arc additive manufacturing

“…The build time in this process is inherently high due to the requirement of changing feedstock wire during deposition. However, this issue can be overcome by adopting a tandem wire-based MIG-WAAM (Gu et al, 2018), (Adinarayanappa and Simhambhatla, 2015). This will also help in fabricating continuous bimetallic objects.…”

A review of wire arc additive manufacturing and advances in wire arc additive manufacturing of aluminium

“…The possibility of application of two welding arcs for improved deposition rate has always been an area of interest from the industry sector. Researchers experimented on the deposition of the WAAM structure with twin-wire GMAW [36] and double-electrode GMAW (DE-GMAW) [37,39]. In comparison between GMAW and DE-GMAW, i.e.…”

“…A comparison of microstructures and mechanical properties of low heat input processes namely cold metal transfer (CMT) and DE-GMAW can benefit the advancement of WAAM. Although simplicity in the formation of functionally graded parts in layer type deposition has been studied [36,38,42], the area is still unattended and needs in-depth understanding of the fundamental behaviour of filler metals of widely different compositions which are mixed using single arc. Even though hybrid manufacturing, the concept that involves the addition of metal and the subsequent removal of part of it to achieve the desired final shape and surface finish, possesses attractive cost advantages and enables interesting real-time repairing during manufacturing, the concept is still underdeveloped.…”