Mechanism to Reduce the Porosity during Argon Arc Welding of Aluminum Alloys by Changing the Arc Angle

Chen, Senchang; Chi, Yan-Hui; Zhang, Ping; Shi, Yusheng

doi:10.3390/met10091121

Cited by 5 publications

(2 citation statements)

References 21 publications

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“…The torch angle towards the substrate is critical and affects various conditions due to the heat loss and the flow force applied to the droplet. According to Chen et al, the difference in torch angle affects the welding pool in a horizontal and vertical direction, and the flow pattern of the molten pool is diverse [23]. Previous studies documented different wire feed directions on the deposit consistency in the additive manufacturing process.…”

Section: Methodsmentioning

confidence: 99%

Build Strategies Based on Substrate Utilization for 3-Axis Hybrid Wire Arc Additive Manufacturing Process

Sarma

Kapil

Joshi

2022

Advances in Materials Science and Engineering

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The hybrid wire arc additive manufacturing (H-WAAM) process is one of the prominent methods for realizing large near-net-shaped metallic objects. In this process, a CAD model of the component is sliced into a set of 2D contours followed by the generation of toolpaths. An arc welding torch then follows these toolpaths for adding material over a substrate to realize the near-net shape of the object. These near-net-shaped objects are then followed by a machining operation to convert them into a fully functional part. It is always anticipated that the near-net shape of an object is produced quickly and upholds a high geometrical accuracy. Conventionally, the deposition rate is increased to reduce the build time but with a compromisation in the geometrical accuracy and material integrity. Therefore, in this work, the authors have investigated three substrate utilization methods, viz., (i) reusable substrate, (ii) embedded substrate, and (iii) integrated substrate to achieve the same goal. The build strategies for these three substrate utilization methods are illustrated through several examples. Also, a case study was performed for fabricating an impeller-like structure through a 3-axis H-WAAM setup. It has been observed that the embedded substrate method exhibits superior geometrical accuracy and takes less time to build the part as compared to other methods. A maximum of 64.34% of the material and 89.17% of build time is saved by adopting proposed build strategies compared with the traditional subtractive process.

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Section: Methodsmentioning

confidence: 99%

Build Strategies Based on Substrate Utilization for 3-Axis Hybrid Wire Arc Additive Manufacturing Process

Sarma

Kapil

Joshi

2022

Advances in Materials Science and Engineering

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“…This adjustment can produce well-formed deposited beads with reduced porosity and other flaws. The mobility of liquid metal causes hydrogen bubbles and molecules from the solidification front in the molten pool to travel together (Chen et al, 2020). The generated structures may fluctuate if the interlayer temperature is too low or too high for a particular lead angle.…”

Section: Torch Anglementioning

confidence: 99%

Bead Geometry Control in Wire Arc Additive Manufactured Profile — A Review

Wani,

Abdullah

2024

JST

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Wire arc additive manufacturing (WAAM) is a well-established additive manufacturing method that produces 3D profiles. A better deposition efficiency can be achieved by understanding the parameters that may influence the geometry of the bead. This paper provides a review that focuses on the factors that may influence the formation of the 3D profile. The included factors are the flow pattern of the molten pool after deposition, the built structure and orientation, the heat input and cooling conditions, the welding parameters, and other uncertainties. This review aims to facilitate a better understanding of these factors and achieve the optimum geometry of the 3D parts produced. According to the literature, the behavior of molten pools is identified as one of the major factors that can impact the deposition efficiency of a bead and govern its geometry. The review indicated that the flow behavior of the molten pool and the geometry of the deposited bead are significantly affected by most welding parameters, such as torch angle, wire travel speed, filler feed rate, and cooling conditions. Furthermore, this paper incorporates the technology utilized for comprehending the behaviors of the molten pool, as it constitutes an integral component of the control strategy. It has been concluded that automated planning and strategy are necessary to ensure efficient deposition by controlling those factors. The integration of artificial intelligence could bring benefits in planning to address the variation and complexity of shapes.

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Non-destructive detection and analysis of weld defects in dissimilar pulsed GMAW and FSW joints of aluminium castings and plates through 3D X-ray computed tomography

Orlando,

De Maddis,

Razza

et al. 2024

Int J Adv Manuf Technol

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This work focuses on porosity formation during the welding of dissimilar aluminium alloys (cast and sheet) by pulsed gas metal arc welding (GMAW) with different travel speeds (12–14 mm/s) and by friction stir welding (FSW). The case study concerns the assembling of a battery-pack enclosure prototype. The welded specimens were scanned by 3D X-ray computed tomography. The cast base material (BM) shows a porosity percentage of 1.45%, and it is characterized by pores with a strong hyperbolic relationship between equivalent diameter and sphericity. Considering the GMAW beads, porosity rises with the travel speed (from 1.80 to 5.12%), due to the reduction of the opening window in which pores can escape. Pores with volume higher than 0.10 mm3 rise with the travel speed, representing from 9.75 to 32.98% of the total porosity. These pores are responsible for the weaker hyperbolic connection for sphericity found for the GMAW beads. On the other hand, FSW mixes and homogenizes the pores in the cast BM. The novelty of the paper lays in proving the strong potentialities of FSW for weld porosity reduction. A re-designing of the battery-pack enclosures is necessary to limit arc welding in marginal areas, which are not crucial for sealing but necessary to create a stable platform to be subsequently sealed with FSW.

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Mechanism to Reduce the Porosity during Argon Arc Welding of Aluminum Alloys by Changing the Arc Angle

Cited by 5 publications

References 21 publications

Build Strategies Based on Substrate Utilization for 3-Axis Hybrid Wire Arc Additive Manufacturing Process

Build Strategies Based on Substrate Utilization for 3-Axis Hybrid Wire Arc Additive Manufacturing Process

Bead Geometry Control in Wire Arc Additive Manufactured Profile — A Review

Non-destructive detection and analysis of weld defects in dissimilar pulsed GMAW and FSW joints of aluminium castings and plates through 3D X-ray computed tomography

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