Forming appearance analysis in multi-layer single-pass GMAW-based additive manufacturing

Xiong, Jun; Zhang, Guangjun; Zhang, Weihua

doi:10.1007/s00170-015-7112-4

Cited by 92 publications

(27 citation statements)

References 15 publications

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“…The mentioned authors credited this to a strong momentum of the backward flow of molten metal in the weld pool that typically occurred during high speed welding as the major factor responsible for the phenomenon, as illustrated in Figure 2. Xiong et al [10] affirmed that the quality of wall formation decreases with the arc mean current (Im) increase. On one hand, as suggested above, WFS, Im, and TS, amongst others, affect the wall quality.…”

Section: Introductionmentioning

confidence: 99%

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Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Yehorov

Silva

Scotti

2019

JMMP

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The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.

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Section: Introductionmentioning

confidence: 99%

“…[14]). Xiong et al [10] affirmed that the quality of wall formation decreases with the arc mean current (Im) increase. On one hand, as suggested above, WFS, Im, and TS, amongst others, affect the wall quality.…”

Section: Introductionmentioning

confidence: 99%

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Yehorov

Silva

Scotti

2019

JMMP

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“…However, the MLSP is different and complicated owing to the use of repeated heating for layer deposition. The previous layer preheats the next layer, while each new layer post-heats the previous layer [17]. The subsequent layers were deposited using the same profile of current, voltage, and travel speed, as explained earlier with the arc-striking currents of 190 A and 170 A, but this resulted in pool flow particularly at the arcextinguishing region, as shown in Figure 8.…”

Section: Multilayer Single-passmentioning

confidence: 99%

“…It has been observed that the current plays a vital role in the stability of pool flow, especially from the second to the fourth layers. Higher currents induce pool overflow, hence collapsing the forming appearance [17]. The parameters are stable in a single layer, become unstable for multiple layers in single passes.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Process Parameters to Improve the Effective Area of Deposition in GMAW-Based Additive Manufacturing and its Mechanical and Microstructural Analysis

Waqas

Qin

Xiong

et al. 2019

Metals

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Additive manufacturing of metals using gas metal arc welding has an associated problem of variations of height in the onset and extinguishing parts of the weld bead. In this research, robot-assisted welding has been performed to investigate the problem, using AWS ER70S-6 low alloy steel welding electrode wire. After adjustment of welding parameters for a single-layer, single-pass, an optimal profile of welding energy was used to construct a thin wall which exhibited good forming characteristics with an effective area of approximately 97%. The resulting structure was ductile in nature with better tensile strength and microhardness as compared to the rolled steel available in industry with similar carbon content. The microstructure analysis revealed equiaxed grains in most parts of the structure having a fine grain size.

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“…However, this equipment and raw materials are usually very expensive, and not conducive to the promotion of application [2][3]. Fabrication of metal fused-coating additives manufacturing (MFCAM) is a new method for fabricating three-dimensional metal functional components [4].…”

Section: Introductionmentioning

confidence: 99%

Morphology Analysis and Process Research on Novel Metal Fused-coating Additive Manufacturing

Wang¹,

Zheng

Du³

et al. 2017

IOP Conf. Ser.: Mater. Sci. Eng.

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Effects of process parameters on the molding quality of the micro-needle array Z J Qiu, Z Ma and S Gao -Process research into metallic pipe wear of hot chamber die casting machines and methods ofincreasing wear resistance G F Mukhametzyanova, MS Kolesnikov, I R Mukhametzyanov et al. Corresponding author: wx624753588@gmail.com Abstract. Existing metal additive manufacturing equipment has high capital costs and slow throughput printing. In this paper, a new metal fused-coating additive manufacturing (MFCAM) was proposed. Experiments of single-track formation were conducted using MFCAM to validate the feasibility. The low melting alloy was selected as the forming material. Then, the effect of process parameters such as the flow rate, deposition velocity and initial distance on the forming morphology. There is a strong coupling effect between the single track forming morphology. Through the analysis of influencing factors to improve the forming quality of specimens. The experimental results show that the twice as forming efficiency as the metal droplet deposition. Additionally, the forming morphology and quality were analyzed by confocal laser scanning microscope and X-ray. The results show that the metal fused-coating process can achieve good surface morphology and without internal tissue defect. IntroductionHigh performance metal components are made of alloy powder or metal wire as raw material, through high power laser or electron beam to layer by layer rapid melting [1]. However, this equipment and raw materials are usually very expensive, and not conducive to the promotion of application [2][3]. Fabrication of metal fused-coating additives manufacturing (MFCAM) is a new method for fabricating three-dimensional metal functional components [4]. To overcome the shortages of traditional AM, metal fused-coating metal additive manufacturing (MCMAM) has been proposed as a commercial manufacturing technology. Compared with traditional metal AM technologies, MCMAM has shown several advantages. At first, it provides a higher material utilization than selective laser melting (SLM) with a high deposition rate. Second, it produces less dust pollution than powder-based equipment when the powder material was recycled. Third, it has a lower equipment cost than SLM and electron beam machining (EBM) [5]. Xiong et al. investigated the forming characteristics of a multilayer single pass with the application of GMAW-based additive manufacturing [6]. Jorge et al. developed a fused deposition modeling (FDM) system for metals that can deposit electronic structures directly [7]. Yao et al. adopted a metal droplet deposition manufacturing process to reduce product development time as well as the cost of manufacturing [8]. However, deposition accuracy was difficult to control. In addition, the novel metal additive manufacturing process proposed in this paper was analyzed using a numerical simulation method. Nevertheless, the influences of process parameters on the forming morphology have never been mentioned [9].

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Forming appearance analysis in multi-layer single-pass GMAW-based additive manufacturing

Cited by 92 publications

References 15 publications

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Optimization of Process Parameters to Improve the Effective Area of Deposition in GMAW-Based Additive Manufacturing and its Mechanical and Microstructural Analysis

Morphology Analysis and Process Research on Novel Metal Fused-coating Additive Manufacturing

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