Evaluating shielding gas-filler wire interaction in bi-metallic wire arc additive manufacturing (WAAM) of creep resistant steel-stainless steel for improved process stability and build quality

Marefat, Fereidoon; Kapil, Angshuman; Banaee, Seyed Aref; Rymenant, Patrick Van; Sharma, Abhay

doi:10.1016/j.jmapro.2023.01.046

Cited by 20 publications

(5 citation statements)

References 34 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…7c). Interlocking, overlapping, or stratified interfaces have been seen and investigated, but in the linear form 35,[37][38][39] . In the context of existing literature, the pattern presented in the current work is unique in its radial form and resultant physics, fundamentally departing from both planar interfaces and bimetallic walls.…”

Section: Discussionmentioning

confidence: 99%

Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing

2023

View full text Add to dashboard Cite

Bimetallic wire arc additive manufacturing (AM) has traditionally been limited to depositions characterized by single planar interfaces. This study demonstrates a more complex radial interface concept, with in situ mechanical interlocking and as-built properties suggesting a prestressed compressive effect. A 308 L stainless core is surrounded by a mild steel casing, incrementally maintaining the interface throughout the Z-direction. A small difference in the thermal expansion coefficient between these steels creates residual stresses at their interface. X-ray diffraction analysis confirms phase purity and microstructural characterization reveals columnar grain growth independent of layer transitions. Hardness values are consistent with thermal dissipation characteristics, and the compressive strength of the bimetallic structures shows a 33% to 42% improvement over monolithic controls. Our results demonstrate that biomimetic radial bimetallic variation is feasible with improved mechanical response over monolithic compositions, providing a basis for advanced structural design and implementation using arc-based metal AM.

show abstract

Section: Discussionmentioning

confidence: 99%

Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing

2023

View full text Add to dashboard Cite

show abstract

“…A reduced lead time and an increased mold life were reported, thus indicating the potential of the multimaterial injection molding process. In more recent work with the utilization of WAAM, the bi-metallic pairs LCS-SS [117] and CRS-SS [118,119] have been successfully fabricated. To manufacture titanium-based alloy and nickel-based alloy bi-metallic components (TC4-IN718), which are widely used in the aerospace industry due to their excellent characteristics, tantalum-copper interlayers were utilized by Wang et al [115] to prevent the formation of Ti-Ni and Ti-Cu compounds at the interface and thus form a good bond at the interface.…”

Section: Bi-metallic Componentsmentioning

confidence: 99%

“…A reduced lead time and an increased mold life were reported, thus indicating the potential of the multi-material injection molding process. In more recent work with the utilization of WAAM, the bi-metallic pairs LCS-SS [117] and CRS-SS [118,119] have been successfully fabricated.…”

Section: Bi-metallic Componentsmentioning

confidence: 99%

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

et al. 2023

Self Cite

View full text Add to dashboard Cite

Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM’s capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

show abstract

“…Speci cally, the gas ow rate, contact tip to work distance (CTWD), and torch angle were set at 20 l/min, 15 mm, and 90°, respectively. These constants were based on their proven performance with the wire-process combination, as demonstrated in a prior in-house study [11].…”

Section: Depositionmentioning

confidence: 99%

Artificial Neural Network-Based Surface Reconstruction Model of Wire-Arc Additively Manufactured Surfaces using Discrete Cosine Transfer

Banaee,

Sharma

2023

Preprint

Self Cite

View full text Add to dashboard Cite

The unique arc-based additive manufacturing process boasts exceptionally high deposition rates, but it comes with a trade-off – the generation of highly irregular surfaces that demand extensive post-machining efforts. These post-processing activities not only consume critical raw materials but also substantial energy resources. To mitigate these challenges and enhance process efficiency, it is crucial to develop predictive capabilities for surface topography based on key process parameters like wire feed speed and travel speed. In this study, a surface topography model is meticulously developed to reconstruct surfaces, utilizing wire feed speed, travel speed, and inter-pass temperature as input parameters. The initial phase involves identifying pertinent surface features that collectively define the surface. Out of the features examined, eight representative attributes emerge, including spatial average roughness, spatial peak height, spatial maximum valley depth, spatial skewness, spatial kurtosis, maximum flatness, and waviness. The surface reconstruction model employs the discrete cosine transform (DCT), necessitating a minimum of 30 DCT parameters for accurate surface reconstruction. Additionally, an ANN model is established to predict DCT parameters based on wire feed speed, travel speed, and inter-pass temperature inputs. Validation using the 309L stainless steel test material demonstrates the model's impressive accuracy in predicting DCT parameters, enabling precise forecasts of overall surface topography and machining allowances. This model lays the foundation for simulation-based additive-subtractive process design by identifying optimal deposition conditions and corresponding machining parameters. Furthermore, it streamlines the integration of realistic surfaces into computational models for additive process simulations, offering significant potential for improving additive manufacturing processes.

show abstract

Evaluating shielding gas-filler wire interaction in bi-metallic wire arc additive manufacturing (WAAM) of creep resistant steel-stainless steel for improved process stability and build quality

Cited by 20 publications

References 34 publications

Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing

Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Artificial Neural Network-Based Surface Reconstruction Model of Wire-Arc Additively Manufactured Surfaces using Discrete Cosine Transfer

Contact Info

Product

Resources

About