Numerical Simulation of Residual Stress Induced by Welding of Steel-Aluminum Transition Joint

Bambach�

2021

Preprint

Wire-Arc Additive Manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased.

Section: Fig 2: Comparison Of the Available [34] And Adapted (For Block) Scatter Chart And Interpolation Function Between Heat Source Tramentioning

confidence: 99%

A Study on Power-Controlled Wire-Arc Additive Manufacturing using a Data-driven Surrogate Model

Bambach�

2021

Preprint

“…All FE analyses were carried out with the *MAT_Thermal_CWM T07 model. The weld beads were modeled using the material properties of steel grade 309L [27], while the substrate was modeled with properties for structural steel S235 [29][30][31]. To model the material deposition on the substrate, the element birth/death technique was implemented in this work.…”

Section: Materials Modelmentioning

confidence: 99%

A Study on Power-Controlled Wire-Arc Additive Manufacturing using a Data-driven Surrogate Model

Bambach

2021

Preprint

Wire-Arc Additive Manufacturing (WAAM) provides an alternative for the production of various metal products needed in small to medium batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased.

Section: Materials Modelmentioning

confidence: 99%

A study on power-controlled wire-arc additive manufacturing using a data-driven surrogate model

Int J Adv Manuf Technol

Bambach

2021

Wire-arc additive manufacturing (WAAM) provides an alternative for the production of various metal products needed in medium to large batch sizes due to its high deposition rates. However, the cyclic heat input in WAAM may cause local overheating. To avoid adverse effects on the performance of the part, interlayer dwelling and active cooling are used, but these measures increase the process time. Alternatively, the temperature during the WAAM process could be controlled by optimizing the welding power. The present work aims at introducing and implementing a novel temperature management approach by adjusting the weld-bead cross-section along with the welding power to reduce the heat accumulation in the WAAM process. The temperature evolution during welding of weld beads of different cross-sections is investigated and a database of the relation between optimal welding power for beads of various sizes and different pre-heating temperatures was established. The numerical results are validated experimentally with a block-shaped geometry. The results show that by the proposed method, the test shape made was welded with lower energy consumption and process time as compared to conventional constant-power WAAM. The proposed approach efficiently manages the thermal input and reduces the need for pausing the process. Hence, the defects related to heat accumulation might be reduced, and the process efficiency increased.