Hot-wire arc additive manufacturing of aluminum alloy with reduced porosity and high deposition rate

Fu, Rui; Tang, Siu Wa; Lu, Jiping; Cui, Yinan; Li, Zixiang; Zhang, Haorui; Xu, Tianqiu; Chen, Zhuo; Liu, Changmeng

doi:10.1016/j.matdes.2020.109370

Cited by 119 publications

(31 citation statements)

References 44 publications

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“…Wire consumables of the 2319 alloy is commercially available, originally developed for joining with 2219 plates and forgings. The 2319 and 2219 alloys are well-suited for WAAM, as demonstrated by several authors [ 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 ] together with the fatigue-resistant 2024 alloy [ 30 , 31 ].…”

Section: Aluminum Alloysmentioning

confidence: 99%

“…This hydrogen source can be eliminated by thermal treatment (decomposition of the hydrated layer) or by laser cleaning [ 68 ]. In-situ resistance heating of the consumable wire shortly before deposition showed promising results with reducing the porosity content in aluminum alloys [ 30 ].…”

Section: Challenges Related To Aluminium Waammentioning

confidence: 99%

“…Vibration of the substrate table was shown by Zhang et al [93] to induce grain refinement and enhanced properties of Al-6Mg WAAM components. Heating of the feedstock wire prior to deposition was attempted to reduce porosity and increase production efficiency [30]. The importance in selection of substrate build material was highlighted by Eimer et al [94].…”

Section: Hardwarementioning

confidence: 99%

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Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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Section: Aluminum Alloysmentioning

confidence: 99%

Section: Challenges Related To Aluminium Waammentioning

confidence: 99%

Section: Hardwarementioning

confidence: 99%

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Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…A common outcome of the pre-heating is the possibility to increase the deposition rate [26,27] or welding efficiency [28]. Additionally, the work performed on Hot-Wire-Arc Additive Manufacturing (HWAAM) indicated that the pre-heating of the feedstock wire contributed to significant reduction in porosity, by limiting pore nucleation sites and creating more favorable conditions for the pores to escape [29]. However, if wire used for deposition was contaminated by greasy dirt and dust particles, the percentage of porosity content increased roughly 30 times, despite the hot-wire being applied [13].…”

Section: Introductionmentioning

confidence: 99%

“…Yet, adding resistive pre-heating increases complexity of the processes making them more susceptible to disturbances. For hot-wire-arc-based technologies, the presence of two currents, the feedstock wire current and the arc current, caused the processes to be easily disturbed [29,31], due to the strong interactions of the created magnetic fields. For laserbased technologies, the two main hot-wire parameters, voltage and current, needed to be tuned carefully.…”

Section: Introductionmentioning

confidence: 99%

Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire

Kisielewicz

Pandian

Sthen

et al. 2021

Metals

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This study investigates the influence of resistive pre-heating of the feedstock wire (here called hot-wire) on the stability of laser-directed energy deposition of Duplex stainless steel. Data acquired online during depositions as well as metallographic investigations revealed the process characteristic and its stability window. The online data, such as electrical signals in the pre-heating circuit and images captured from side-view of the process interaction zone gave insight on the metal transfer between the molten wire and the melt pool. The results show that the characteristics of the process, like laser-wire and wire-melt pool interaction, vary depending on the level of the wire pre-heating. In addition, application of two independent energy sources, laser beam and electrical power, allows fine-tuning of the heat input and increases penetration depth, with little influence on the height and width of the beads. This allows for better process stability as well as elimination of lack of fusion defects. Electrical signals measured in the hot-wire circuit indicate the process stability such that the resistive pre-heating can be used for in-process monitoring. The conclusion is that the resistive pre-heating gives additional means for controlling the stability and the heat input of the laser-directed energy deposition.

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Microstructure, Mechanical Properties, and Corrosion Behavior of Co‐Based Stellite 6 Multilayer Overlays Deposited on ASTM A36 Steel by Gas Metal Arc Welding Process

Sankarapandian¹,

Kumar

Kannan

et al. 2023

steel research int.

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Hardfacing is an effective method for restoring the damaged part. Herein, cobalt‐based superalloy Stellite‐6 is deposited on A36 substrate using gas metal arc welding process. The mechanical properties, microstructure, and corrosion behavior of Stellite‐6 overlays on A36 substrate are examined. Defect‐free hard overlays are obtained, and a dilution ratio of 19.9% is achieved with weaving technique. X‐ray diffraction analysis reveals the presence of M7C3, M23C6, M6C, and martensite in the Stellite‐6 hard overlays. The microstructure of the deposit contains martensite, carbides, and interdendritic precipitates while the mean hardness is 471 HV0.5. Tensile testing with specimens extracted on the longitudinal (LD) and transverse (TD) orientation of the stellite‐6 deposit shows a strength above 950 MPa along with the brittle nature of fracture. Grain growth is epitaxial and shows dendritic morphologies. The higher fraction of high‐angle grain boundaries improves the tensile strength of the deposit and interface region. The localized corrosion behavior of stellite‐6 hard overlays is found to be excellent, and the corrosion analysis exhibits a corrosion rate of 0.10 mils per year (mpy). The outcomes of the study highlight the feasibility of Stellite‐6 hard overlays for extending the service life of A36 steel in chloride environments.

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Hot-wire arc additive manufacturing of aluminum alloy with reduced porosity and high deposition rate

Cited by 119 publications

References 44 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire

Microstructure, Mechanical Properties, and Corrosion Behavior of Co‐Based Stellite 6 Multilayer Overlays Deposited on ASTM A36 Steel by Gas Metal Arc Welding Process

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