Hybrid manufacturing of components from Ti-6Al-4V by metal forming and wire-arc additive manufacturing

Bambach�, Markus; Sizova, Irina; Sydow, Benjamin�; Hemes, Susanne; Meiners, Frank

doi:10.1016/j.jmatprotec.2020.116689

Cited by 114 publications

(32 citation statements)

References 17 publications

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“…Each wall microstructure in Figure 12 show that the prior β grains grow epitaxially in the build direction with dimensions varying from 100 µm to 7000 µm; the same β-grain morphology was found as is usual in WAAM-produced structures by other researchers [ 41 , 42 , 43 ]. The average coarse β-grain height is 3000 µm in the CMT and CSC walls, while the average coarse β-grain height in the DCEN wall is 4300 µm.…”

Section: Resultssupporting

confidence: 75%

Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

et al. 2021

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In wire arc additive manufacturing of Ti-alloy parts (Ti-WAAM) gas metal arc welding (GMAW) can be applied for complex parts printing. However, due to the specific properties of Ti, GMAW of Ti-alloys is complicated. In this work, three different types of metal transfer modes during Ti-WAAM were investigated: Cold Metal Transfer, controlled short circuiting metal transfer, and self-regulated metal transfer at a direct current with a negative electrode. Metal transfer modes were studied using captured waveform and high-speed video analysis. Using these modes, three walls were manufactured; the geometry preservation stability was estimated and compared using effective wall width calculation, the microstructure was analyzed using optical microscopy. Transfer process data showed that arc wandering depends not only on cathode spot instabilities, but also on anode processing properties. Microstructure analysis showed that each produced wall consists of phases and structures inherent for Ti-WAAM. α-basketweave in the center of and α-colony on the grain boundary of epitaxially grown β-grains were found with heat affected zone bands along the height of the walls, so that the microstructure did not depend on metal transfer dramatically. However, the geometry preservation stability was higher in the wall, produced with controlled short circuiting metal transfer.

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Section: Resultssupporting

confidence: 75%

Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

et al. 2021

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“…It has been reported that in non-HIP samples, exposed pores can hold contaminants that can leave defects during plating and harbour bacteria in medical applications. Therefore, HIP treatments are successful at enhancing the cleanliness and better polishing results can be achieved on processed surfaces, and thus to improve the surface integrity of components [27,28]. Furthermore, steels especially SS are widely used in the aerospace sector to produce engine and/or exhaust components, due to their superior high temperature tolerances and their good corrosion resistance.…”

Section: Application Areas Of Hybrid 316 L Stainless Steelmentioning

confidence: 99%

“…Furthermore, repeatability and microstructural consistency of produced hybrid components were not investigated and their surface integrity and mechanical performance were not optimised. Other researchers have attempted HCM, but success has been limited to manufacturing one-off component manufacture or to process planning without full investigations into components mechanical properties or optimisation [25][26][27][28].…”

Section: Introductionmentioning

confidence: 99%

The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components

et al. 2021

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Hybrid manufacture of components by combining capabilities of replication and additive manufacturing processes offer a flexible and sustainable route for producing cost-effectively small batches of metal parts. At present, there are open issues related to surface integrity and performance of such parts, especially when utilising them in safety critical applications. The research presented in this paper investigates the ductility amplification of hybrid components produced using metal injection moulding to preform and then build on them customisable sections by laser-based powder bed fusion. The properties of such hybrid components are studied and optimised through the use of non-conventional post treatment techniques. In particular, hot isostatic pressing (HIP) is employed to improve mechanical strength and to produce hybrid components that have consistent properties across batches and throughout the samples, minimising microstructural heterogeneities between fabrication processes. Thus, the investigated post-processing method can offer an extended service life of hybrid components, especially when operating under severe conditions. The optimised post treatment was found to increase the hybrid components’ strength compared to as-built ones by 68% and ~11% in yield strength (YS) and ultimate tensile strength (UTS), respectively. Subsequently, leading to a great pitting resistance, thus, making HIP samples suitable for corrosive environments. The advantages of the HIP treatments in comparison to the conventional heat treatment of hybrid components are discussed and also some potential application areas are proposed.

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“…High forming accuracy has been achieved for thin-walled components (single-bead multi-layer components), 17,18 as well as high flatness of single-layer multi-bead weld surfaces, 19 and various paths planning algorithm have been proposed for different geometric shapes. 20 In contrast, the forming accuracy and surface flatness of multi-layer multi-bead (MLMB) components are generally low. This has prompted further studies on the MLMB forming process.…”

Section: Introductionmentioning

confidence: 99%

An automatic compensation method for improving forming precision of multi-layer multi-bead component

Zhao

Liu

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Wire and arc additive manufacturing (WAAM) is a promising technology for manufacturing large-sized metal components. However, the material shortage region (MSR) at the edge of each slicing layer can influence the forming precision and surface flatness of components. To solve these problems, this paper proposes a shape follow-up edge cycle compensation (SECC) method and model for predicting the weld width and weld height to improve the efficiency of the WAAM process. First, the prediction model was used to determine the weld width and weld height for various welding parameters. The predicted width was then used to obtain the optimal overlap distance, and the filling path of each layer was generated. The same weld height was used for slicing of the 3D model and the tool path compensation cycle was generated. Second, the influence of the MSR on the morphology of multi-layer multi-bead (MLMB) components was analyzed. The MSR results in a height difference between the edge height and the middle height of every deposited layer, and the height difference increases as more layers are added and the height of the component increases. Furthermore, the influence of the MSR gradually extends from the edge to the middle, such that the upper surface presents a parabolic shape. Finally, a mathematical model was established to determine the height difference based on the area of the MSR. When the height difference reaches the weld height, an edge compensation weld is added to eliminate the height difference. Our experimental results show that the proposed forming control strategy improves forming precision and surface flatness. The method is highly feasible and can be applied to a wide range of WAAM applications.

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Hybrid manufacturing of components from Ti-6Al-4V by metal forming and wire-arc additive manufacturing

Cited by 114 publications

References 17 publications

Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V

The Effect of Hot Isostatic Pressing on Surface Integrity, Microstructure and Strength of Hybrid Metal Injection Moulding, and Laser-Based Powder Bed Fusion Stainless-Steel Components

An automatic compensation method for improving forming precision of multi-layer multi-bead component

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