Modelling and experimental observation of the deposition geometry and microstructure evolution of aluminum alloy fabricated by wire-arc additive manufacturing

Geng, Ruwei; Du, Jun; Wei, Zhengying; Xu, Siyuan; Ma, Ninshu

doi:10.1016/j.jmapro.2021.01.037

Cited by 29 publications

(13 citation statements)

References 23 publications

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“…Finite Element Analysis, a well-known technique, focuses on modelling macroscopic phenomena, from a cluster point of view. The input parameters vary from study to study, but throughout the approaches, the main disadvantage is the reduced sensitivity of the method [28,34,37].…”

Section: Literature Review On Modelling For Ammentioning

confidence: 99%

Developing a Framework for Using Molecular Dynamics in Additive Manufacturing Process Modelling

Stavropoulos

Panagiotopoulou

2022

Modelling

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Additive Manufacturing (AM), or else Smart Manufacturing, has been an intrinsic concept in Industry 4.0, offering flexibility and material efficiency. Certain limitations prevent AM from being used in the industrial setting extensively, despite its advantages. Therefore, a literature review on the process modelling approaches, their advantages and limitations was performed. The most frequently used process modelling approaches were reviewed and summarized with respect to the process modelling approach, scale and limitations. The different categories of process modelling approaches were compared, with molecular dynamics being a promising modelling technique that can be used in software applications. A new framework for modelling additive manufacturing processes based on molecular dynamics was proposed in this work, combining previously published manufacturing methodologies for the AM process, such as manufacturability, design and planning of the AM. A validation plan followed, with the main parameters and details highlighted. The proposed framework is offering a unique approach for modelling the AM process, based on parameters from the manufacturing design, planning and process. This framework will be used in software platforms for predicting temperature distributions and for optimizing shape and AM process.

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Section: Literature Review On Modelling For Ammentioning

confidence: 99%

Developing a Framework for Using Molecular Dynamics in Additive Manufacturing Process Modelling

Stavropoulos

Panagiotopoulou

2022

Modelling

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“…However, there was a significant difference in the solidification conditions between the SLM and WAAM processes, such as temperature gradient (G), 4 solidification rate (R), and cooling rate (ɛ). The G in SLM [24]and WAAM [9,25]is 10 5 -10 6 K/m and 10 4 -10 5 K/m, respectively. The R in SLM and WAAM is ~1 m/s and ~10 -3 m/s, respectively.…”

Section: Introductionmentioning

confidence: 99%

The heterogeneous band microstructure and mechanical performance in a wire + arc additively manufactured 2219 Al alloy

Zhou

Lin

Kang

et al. 2022

Additive Manufacturing

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“…Melt pool or mesoscale models can describe partial aspects of the process in detail [ 14 , 15 ], but FEM can also be used for macroscale models to understand the overall temperature progression and deformations during the process [ 16 , 17 , 18 , 19 , 20 ]. The heating process has been the subject of several studies [ 21 , 22 , 23 , 24 , 25 ] which allow us to understand more in detail the physical phenomena and to determine the relevance of the meso and microscale modeling. The microscale process has been investigated by Geng et al in [ 21 ], where FE were combined with a microscopic phase field (PF) model that allowed the determination of the temperature distribution field and the effects of the microstructure evolution during a melting phase process for a wire arc additive manufacturing process (WAAM).…”

Section: Introductionmentioning

confidence: 99%

“…The heating process has been the subject of several studies [ 21 , 22 , 23 , 24 , 25 ] which allow us to understand more in detail the physical phenomena and to determine the relevance of the meso and microscale modeling. The microscale process has been investigated by Geng et al in [ 21 ], where FE were combined with a microscopic phase field (PF) model that allowed the determination of the temperature distribution field and the effects of the microstructure evolution during a melting phase process for a wire arc additive manufacturing process (WAAM). The PF model can be combined with both FE and computational fluid dynamics (CFD), and it proved to be effective in evaluating the evolution of the chemical composition through concentration field equations and grain morphology, allowing for the determination of the quality of the microstructure by the temperature evolution.…”

Section: Introductionmentioning

confidence: 99%

FEM Simulation of AlSi10Mg Artifact for Additive Manufacturing Process Calibration with Industrial-Computed Tomography Validation

Patuelli,

Cestino,

Frulla

et al. 2023

Materials

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Dimensional accuracy of selective laser melting (SLM) parts is one of manufacturers’ major concerns. The additive manufacturing (AM) process is characterized by high-temperature gradients, consolidation, and thermal expansion, which induce residual stress on the part. These stresses are released by separating the part from the baseplate, leading to plastic deformation. Thermo-mechanical finite elements (FE) simulation can be adopted to determine the effect of process parameters on final geometrical accuracy and minimize non-compliant parts. In this research, a geometry for process parameter calibration is presented. The part has been manufactured and then analyzed with industrial computed tomography (iCT). An FE process simulation has been performed considering material removal during base plate separation, and the computed distortions have been compared with the results of the iCT, revealing good accordance between the final product and its digital twin.

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Modelling and experimental observation of the deposition geometry and microstructure evolution of aluminum alloy fabricated by wire-arc additive manufacturing

Cited by 29 publications

References 23 publications

Developing a Framework for Using Molecular Dynamics in Additive Manufacturing Process Modelling

Developing a Framework for Using Molecular Dynamics in Additive Manufacturing Process Modelling

The heterogeneous band microstructure and mechanical performance in a wire + arc additively manufactured 2219 Al alloy

FEM Simulation of AlSi10Mg Artifact for Additive Manufacturing Process Calibration with Industrial-Computed Tomography Validation

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