Oxidation in wire arc additive manufacturing of aluminium alloys

Hauser, Tobias; Reisch, Raven T.; Breese, Philipp P.; Nalam, Yogesh; Joshi, Kaivalya S.; Bela, Katharina; Kamps, Tobias; Volpp, Jöerg; Kaplan, Alexander

doi:10.1016/j.addma.2021.101958

Cited by 20 publications

(10 citation statements)

References 21 publications

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“…Therefore, it was expected that the laser absorption would change due to the surface oxidation and PSD, impacting the process conditions and the final sample properties. Furthermore, the literature claimed that such surface oxidation is typical for highly reactive materials such as titanium [ 6 ], nickel [ 10 , 36 ], and aluminium alloys [ 37 ]. However, the results shown above demonstrate that the analysed AlSi7Mg0.6 powder is highly stable in terms of the laser absorption level during five consecutive LPBF processes.…”

Section: Discussionmentioning

confidence: 99%

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.

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Section: Discussionmentioning

confidence: 99%

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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“…Geometrical fluctuations often occur due to process temperatures that are too low or too high [3]. Oxidation effects can reduce the mechanical properties of the part and occur in particular in WAAM of aluminium due to the high affinity of aluminium with oxygen [18].…”

Section: Acoustic Emissions In Directed Energy Deposition Processesmentioning

confidence: 99%

Acoustic emissions in directed energy deposition processes

Hauser

Reisch

Kamps

et al. 2022

Int J Adv Manuf Technol

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Acoustic emissions in directed energy deposition processes such as wire arc additive manufacturing and directed energy deposition with laser beam/metal are investigated within this work, as many insights about the process can be gained from this. In both processes, experienced operators can hear whether a process is running stable or not. Therefore, different experiments for stable and unstable processes with common process anomalies were carried out, and the acoustic emissions as well as process camera images were captured. Thereby, it was found that stable processes show a consistent mean intensity in the acoustic emissions for both processes. For wire arc additive manufacturing, it was found that by the Mel spectrum, a specific spectrum adapted to human hearing, the occurrence of different process anomalies can be detected. The main acoustic source in wire arc additive manufacturing is the plasma expansion of the arc. The acoustic emissions and the occurring process anomalies are mainly correlating with the size of the arc because that is essentially the ionized volume leading to the air pressure which causes the acoustic emissions. For directed energy deposition with laser beam/metal, it was found that by the Mel spectrum, the occurrence of an unstable process can also be detected. The main acoustic emissions are created by the interaction between the powder and the laser beam because the powder particles create an air pressure through the expansion of the particles from the solid state to the liquid state when these particles are melted. These findings can be used to achieve an in situ quality assurance by an in-process analysis of the acoustic emissions.

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“…Although these effects are tried to be minimized by optimizing the parameters, many studies have stated that this problem is inevitable for the production of aluminum alloys by the WAAM process. For example, Hauser et al [31] investigated the oxidation problem in the production of AW4043/AlSi5(wt%) by the waam process. They supported experimental observations with CFD (Computational Fluid Dynamics) simulation.…”

Section: Microhardnessmentioning

confidence: 99%

Wire Arc Additive Manufacturing Of 5356 Aluminum Alloy

Bozkurt¹,

ÖZDEMİR²,

KALENDER³

2022

Preprint

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Additive manufacturing technology is a new technology that is considered to be a technological revolution in the manufacturing industry. It has advantages such as design flexibility, saving material and time, producing low-density and high-strength parts. Due to these advantages it is used in many sectors such as aviation and automotive. The additive manufacturing method can be integrated into different welding methods. One of these technologies is wire arc additive manufacturing (WAAM). Metal inert/active gas (MIG/MAG) or tungsten inert gas (TIG) welding methods are generally used in this method. The basic principle of the WAAM method is to melt the raw material in the form of wire with electric arc heat and deposit it in layers on top of each other. The fact that large-sized and complex parts can be produced without any problems, almost no waste, and being economical compared to other metal additive manufacturing methods has made this technique a demanding production method.In this study, AA5356 aluminum alloy wires with a diameter of 2.4 mm were deposited on plates under argon gas by TIG welding method and jointed aluminum parts were produced with different welding parameters. As a result of tests and microstructure investigations, it was determined that the samples prepared parallel and perpendicular to the weld seam direction showed different behavior in terms of mechanical properties. These results were supported by the microstructure and compared with the parts produced by traditional methods. In addition mechanical tests and microstructural examinations were supported by EBSD, EDS and AFM analyzes.

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Oxidation in wire arc additive manufacturing of aluminium alloys

Cited by 20 publications

References 21 publications

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Acoustic emissions in directed energy deposition processes

Wire Arc Additive Manufacturing Of 5356 Aluminum Alloy

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