Gas metal arc welding based additive manufacturing—a review

Pattanayak, Suvranshu; Sahoo, Susanta Kumar

doi:10.1016/j.cirpj.2021.04.010

Cited by 106 publications

(33 citation statements)

References 113 publications

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“…Most recently, the MIG-based WAAM system has seen the most advancement, with a high degree of freedom making this approach easier to manipulate (Kozamernik et al, 2020), (Warsi et al, 2022). MIG-based WAAM has also gained significant interest over TIG and PAW-based systems due to increased bonding strength, higher energy efficiency, and a faster metal deposition rate that results in a reduced printing time (Pattanayak and Sahoo, 2021). The feasibility of printing steel parts using a MIGbased dual electrode WAAM system (Yang et al, 2016), as well as the impact of the critical deposition process parameters on the surface roughness of low-carbon steel parts manufactured using a MIG-based WAAM, have been investigated (Xiong et al, 2018).…”

Section: Introductionmentioning

confidence: 99%

Influence of active cooling on microstructure and mechanical properties of wire arc additively manufactured mild steel

et al. 2023

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Additive manufacturing (AM) of metals attracts attention because it can produce complex structures in a single step without part-specific tooling. Wire arc additive manufacturing (WAAM), a welding-based method that deposits metal layer by layer, is gaining popularity due to its low cost of operation, feasibility for large-scale part fabrication, and ease of operation. This article presents the fabrication of cylindricalshaped mild steel (ER70S-6) samples with a gas metal arc (MIG)—based hybrid WAAM system. A mechanism for actively cooling the substrate is implemented. Deposition parameters are held constant to evaluate the impact of active cooling on deposition quality, inter-pass cooling time, and internal defects. Surface and volume defects can be seen on the cylindrical sample fabricated without an active cooling setup. Defect quantification and phase analysis are performed. The primary phase formed was α-iron in all samples. Actively cooled deposition cross section showed a 99% decrease of incomplete fusion or porosity, with temperature measured 60 s after deposition averaging 235°C less than non-cooled. Microstructural analysis revealed uniformity along the build direction for actively cooled deposition but non-uniform microstructures without cooling. Hardness decreased by approximately 22HV from the first layer to the final layer in all cases. Property variation can be attributed to the respective processing strategies. The current study has demonstrated that active cooling can reduce production time and porosity while maintaining uniform microstructure along the build direction. Such an approach is expected to enhance the reliability of WAAM-processed parts in the coming days.

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Section: Introductionmentioning

confidence: 99%

Influence of active cooling on microstructure and mechanical properties of wire arc additively manufactured mild steel

et al. 2023

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“…GMAW, commonly known as MIG (metal inert gas) welding, is a technology that allows welders to weld non-ferrous materials. With its excellent energy efficiency, deposition rate, material usage, and short production time, GMAW-based additive manufacturing is now frequently used over other AM techniques [20]- [22]. Wang et al [23], Ding et al [24], and Cunningham et al [25] demonstrated that GMAW based AM process had more benefits than laser beam-based, electron beam-based, GTAW-based, and plasma arc welding-based AM processes due to its high deposition rate, reduction of manufacturing cost, and environmental friendliness.…”

Section: Gas Metal Arc Welding (Gmaw)mentioning

confidence: 99%

Process and Heat Resources for Wire Arc Additive Manufacturing of Aluminium Alloy ER4043: A Review

Hussein¹,

Ket²,

Rahim³

et al. 2023

JMechE

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The application of wire arc additive manufacturing (WAAM) in manufacturing has raised interest among researchers. In this paper, the introduction of additive manufacturing and wire arc additive manufacturing, various heat resources for WAAM, aluminium alloys, aluminium alloys ER4043, and performance evaluation of WAAM of ER4043 have been discussed in detail based on bead geometry, microstructure, microhardness, and tensile properties as well as the building path strategies, problems, and future directions. Based on this review, aluminium alloy 4043 (ER4043) is an Al-Si alloy frequently employed as a filler wire because it has superior fluidity and significantly fewer flaws in additively built structures. Next, dwell time and cooling efficiency during the WAAM process significantly affect bead geometry. Besides, a finer microstructure can be obtained with a better cooling rate. However, a coarser microstructure is obtained along with the increased deposition height due to heat accumulation and low solidification rate. Heat input is identified as the main cause of porosity, and CMT with a lower heat input is preferable and outperformed GTAW and GMAW in terms of mechanical properties.

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“…WAAM technology is mainly based on three welding methods, namely metal inert gas welding (MIG), tungsten inert gas welding (TIG), and plasma arc welding (PAW) [4]. Among them, the WAAM technology based on MIG welding has the highest energy utilisation rate, good forming effect, and fast forming speed, so it is the most widely used among the three WAAM technologies [5,6]. In order to better solve the problems of high heat input and easy generation of spatter during MIG welding, Fronius has improved the MIG welding process and developed a cold metal transfer (CMT) welding technology, which can effectively solve the above problems, especially suitable for aluminium alloy welding [7,8].…”

Section: Introductionmentioning

confidence: 99%

Influence of assisted longitudinal magnetic field on the microstructure and mechanical properties of ER2319 aluminium alloy parts fabricated by wire and arc additive manufacturing

Zhang

Zhao

Long

et al. 2023

Science and Technology of Welding and Joining

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The deposit morphology, microstructure, and mechanical properties of wire and arc additive manufacturing (WAAM) of ER2319 aluminium alloy with and without assisted longitudinal magnetic field (ALMF) were investigated comprehensively and comparatively in this study. The results showed that the ALMF improved the surface forming accuracy slightly, and effectively promoted the equiaxed transformation of grains. Simultaneously, the introduction of ALMF is beneficial to improving the morphology and distribution of the strengthening phase and reducing the tendency of intergranular corrosion caused by the segregation of Cu elements along the grain boundaries. Moreover, ALMF can remarkably reduce the generation rate of large pores, thereby effectively improving the tensile strength of the deposits and reducing the anisotropy of mechanical properties.

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Gas metal arc welding based additive manufacturing—a review

Cited by 106 publications

References 113 publications

Influence of active cooling on microstructure and mechanical properties of wire arc additively manufactured mild steel

Influence of active cooling on microstructure and mechanical properties of wire arc additively manufactured mild steel

Process and Heat Resources for Wire Arc Additive Manufacturing of Aluminium Alloy ER4043: A Review

Influence of assisted longitudinal magnetic field on the microstructure and mechanical properties of ER2319 aluminium alloy parts fabricated by wire and arc additive manufacturing

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