Optimization of CMT Characteristic Parameters for Swing Arc Additive Manufacturing of AZ91 Magnesium Alloy Based on Process Stability Analysis

Abstract

The droplet transfer behavior and stability of the swing arc additive manufacturing process of AZ91 magnesium alloy based on the cold metal transfer (CMT) technique were studied by analyzing the electrical waveforms and high-speed droplet images as well as the forces on the droplet, and the Vilarinho regularity index for short-circuit transfer (IVSC) based on variation coefficients was used to characterize the stability of the swing arc deposition process. The effect of the CMT characteristic parameters on the process stability was investigated; then, the optimization of the CMT characteristic parameters was realized based on the process stability analysis. The results show that the arc shape changed during the swing arc deposition process; thus, a horizontal component of the arc force was generated, which significantly affected the stability of the droplet transition. The burn phase current I_sc_wait presented a linear function relation with IVSC, while the other three characteristic parameters, i.e., boost phase current I_boost, boost phase duration t_I_boost and short-circuiting current I_sc2, all had a quadratic correlation with IVSC. A relation model of the CMT characteristic parameters and IVSC was established based on the rotatable 3D central composite design; then, the optimization of the CMT characteristic parameters was realized using a multiple-response desirability function approach.

Effects of Contaminations on Electric Arc Behavior and Occurrence of Defects in Wire Arc Additive Manufacturing of 316L-Si Stainless Steel

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Effect of Current Waveforms during Directed Energy Deposition of 4043 Aluminum Alloy on Microstructure, Hardness, and Wear of Alloy

“…They determined the ideal EP/EN ratio, which yielded optimal forming accuracy and ensured stable deposition, to be 13:7. Zhang et al [18] examined the metal transfer behavior and stability in the swing arc additive manufacturing of AZ91 magnesium alloy through the CMT process. They analyzed electrical waveforms, high-speed images of the weld pool, and forces acting on the droplet to achieve optimum parameters for stable deposition.…”