Modeling and simulation of heat transfer, fluid flow and geometry morphology in GMAW-based wire arc additive manufacturing

Zhao, Wenjin; Wei, Yanhong; Long, Jinwei; Chen, Jicheng; Liu, Renpei; Ou, Wenmin

doi:10.1007/s40194-021-01123-1

Cited by 24 publications

(4 citation statements)

References 35 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The model employed multilayer deposition using the surface reconstruction technique after each layer had been built. In the case of gas metal arc welding (GMAW)-WAAM, a similar framework was employed, though arc plasma was neglected [135]. The simulation results illustrated droplet detachment and droplet impact on melt pool.…”

Section: High-fidelity Multiphysics Modelsmentioning

confidence: 99%

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Sharma

Joshi

Pantawane

et al. 2023

International Materials Reviews

View full text Add to dashboard Cite

This review article provides a critical assessment of the progress made in computational modelling of metal-based additive manufacturing (AM) with emphasis on its ability to predict physical phenomena, concepts of microstructural evolution, residual stresses, role of multiple thermal cycles, and formation of multi-dimensional defects along with the achieved degree of experimental validation. The uniqueness of this article stems from the inclusion of comprehensive information on computational progress in the field of fusion-based, sintering-based, and mechanical deformation-based AM. A computational model's role in determining the process framework for the desired outcome of the set properties of the AM components is recognised while presenting the process-microstructure maps, thereby appraising computational ability towards the qualification of products. The inclusion of a detailed discussion on the bi-directional coupling of machine learning and physics-based computational models provides a futuristic roadmap for the digital twin of metal-based AM.

show abstract

Section: High-fidelity Multiphysics Modelsmentioning

confidence: 99%

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Sharma

Joshi

Pantawane

et al. 2023

International Materials Reviews

View full text Add to dashboard Cite

show abstract

“…The mechanisms in uencing the molten pool ow were investigated and simulated in various conditions of driving forces [26], undercut formation [27], transverse magnetic eld [28], arc interactions [29], groove shape [30], double-sided [31], double-shielded [32], and double-pulsed [33] GMAW. The improvement of numerical models is still ongoing, especially in the topics such as wire-arc additive manufacturing (WAAM) [34,35], where new industrial applications are emerging.…”

Section: Introductionmentioning

confidence: 99%

Effect of workpiece vibration frequency on heat distribution and material flow in the molten pool in tandem-pulsed gas metal arc welding

Hamed Zargari,

Ito,

Sharma

2023

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Versatility, high deposition rate, ne quality, and low equipment cost are known features of the tandem-pulsed gas metal arc welding (TP-GMAW) process. Concurrently, vibration-assisted welding has been considered one of the trends in developing advanced industrial concepts. This study presents a three-dimensional model of the TP-GMAW process to investigate heat transfer and material ow. The competition between the heat distribution beneath the surface and the physical movement caused by the workpiece sine-mode vibration are traced and discussed to understand how the penetration shape change was determined. It is found that applying the vibration extends the heat distribution along the welding direction beneath the weld pool surface, and this trend increases with increasing vibration frequency and effective heat input. In contrast, the heat extending is minimum in the sample without vibration having the highest heat input. This inconsistency can be explained by the physical movement of material in a molten pool due to the workpiece vibration. The vibration also changes the material ow from the surface to the depth in the central rear areas, although it follows an opposite direction in the sample without vibration. Thus, the material ow is vital in improving the penetration shape. DeclarationsAcknowledgements: The investigation results from a joint research program between the Joining and Welding

show abstract

“…Most of the above experimental and simulation studies on arc shape and stability are focused on welding or multi-pass multi-layer WAAM arc. However, the research reports related to single-pass multi-layer WAAM mainly focus on the heat and mass transfer, the flow of molten pool, and the microstructure and properties [25,26].…”

Section: Introductionmentioning

confidence: 99%

Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing

Zhou

Zhang

Peng

et al. 2022

Metals

View full text Add to dashboard Cite

The single-pass multi-layer depositing strategy is usually used to fabricate thin-wall structures with wire and arc additive manufacturing (WAAM) technology. Various deposited wall thicknesses often lead to a change in arc shrinkage in the wall thickness direction, which affects the arc shape and stability, and even the microstructure and properties. To systematically study the effect of wall thickness (δ) on arc shape and stability, 3D numerical models were established, with wall thickness varying from 1 to 14 mm during the WAAM process. The characteristics of the arc shape, temperature field, velocity field, current density, and the electromagnetic force were investigated. When δ is smaller than the arc diameter (Φ), the thinner wall will result in a longer arc along the deposition direction. When δ is greater than the Φ, the arc shape tends to be a bell shape. When δ < Φ, the peak temperature in the arc centre, the peak current density, and the electromagnetic intensity along the welding direction decreased with the increase in the wall thickness. However, the opposite observations were found when δ < Φ. The simulation results are consistent with the actual arc shape collected and showed that when δ is slightly less than Φ, the forming quality of the deposited wall is the best. The research in this paper can fill the research gap and provide a theoretical basis for the matching selection of process parameters and wall thickness in WAAM applications.

show abstract

Modeling and simulation of heat transfer, fluid flow and geometry morphology in GMAW-based wire arc additive manufacturing

Cited by 24 publications

References 35 publications

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Effect of workpiece vibration frequency on heat distribution and material flow in the molten pool in tandem-pulsed gas metal arc welding

Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing

Contact Info

Product

Resources

About