Pore formation and evolution in wire + arc additively manufactured 2319 Al alloy

Gu, Jianglong; Gao, Minjie; Yang, Shouliang; Bai, Jintao; Ding, Jialuo; Fang, Xuewei

doi:10.1016/j.addma.2019.100900

Cited by 46 publications

(24 citation statements)

References 37 publications

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“…The relatively poor dimensional accuracy is another unfavorable impact for the wide application of WAAM [ 25 , 26 ]. For overcoming the above shortcomings, many researches focusing on dimensional and microstructure control of components were conducted for the WAAM process [ 27 , 28 , 29 ]. Dai et al [ 30 ] studied the slicing and scanning strategies of the WAAM process for manufacturing a multi-directional pipe joint, and successfully controlled the dimensional errors within ±1 mm.…”

Section: Introductionmentioning

confidence: 99%

Microstructure Evolution and Mechanical Properties of a Wire-Arc Additive Manufactured Austenitic Stainless Steel: Effect of Processing Parameter

et al. 2021

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Two single track multi-layer walls with linear energy inputs (LEIs) of 219 and 590 J/mm were deposited by cold metal transfer-based wire arc additive manufacturing system. Combined with the X-ray diffraction technique, scanning electron microscope and uniaxial tensile tests, the influences of LEI and cooling rate (CR) on the microstructure evolution, mechanical properties and fracture mechanisms of the studied steel are analyzed. It is observed that the microstructures of the studied steel are mainly composed of δ-ferrite and austenite dendrites. σ phase is formed on the δferrite–austenite interface under low CR. Meanwhile, the primary dendrites’ spacing decreases with the decrease in LEI or the increase in CR, and the maximal primary dendrites’ spacing is 32 μm. The values of elongation to fracture roughly decline with the decrease in LEI or the increase in CR, but the variations of ultimate tensile strength and yield stress show an opposite trend. In addition, the mesoscopic damages in the studied steel under low LEI are mainly caused by the coalescence of pores. While under high LEI, the cracks are induced by the dislocations piling up around δ-ferrite.

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Section: Introductionmentioning

confidence: 99%

Microstructure Evolution and Mechanical Properties of a Wire-Arc Additive Manufactured Austenitic Stainless Steel: Effect of Processing Parameter

et al. 2021

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“…Wire consumables of the 2319 alloy is commercially available, originally developed for joining with 2219 plates and forgings. The 2319 and 2219 alloys are well-suited for WAAM, as demonstrated by several authors [ 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 ] together with the fatigue-resistant 2024 alloy [ 30 , 31 ].…”

Section: Aluminum Alloysmentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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“…The laser profile scanner device and its measurement flow chart are shown in Figure 3. According to a previous CMT-based WAAM study (Gu et al, 2019), the range of process parameters is given in Table 2. The abrupt change of process parameters can be used to avoid defects in the future when in-situ monitoring systems are established.…”

Section: Experimental Design 231mentioning

confidence: 99%

“…Favorable thermal conductivity, low melting point and high reflectivity of laser are intrinsic attributes of aluminum and its alloys. In this regard, wire and arc additive manufacturing (WAAM) is thought to be a promising building method for large components owing to its high deposition rate and material utilization rate, together with comparatively low production and equipment costs, in different AM processes (Derekar, 2018;Gu et al, 2019;Ye et al, 2013). WAAM has been recognized as one of the most efficient methods for fabricating large components of up to several meters, such as cruciform components, stiffened panels and wing ribs.…”

Section: Introductionmentioning

confidence: 99%

A model of bead size based on the dynamic response of CMT-based wire and arc additive manufacturing process parameters

Fang¹,

Ren²,

Zhang³

et al. 2021

RPJ

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Purpose This paper aims at fabricating large metallic components with high deposition rates, low equipment costs through wire and wire and arc additive manufacturing (WAAM) method, in order to achieve the morphology and mechanical properties of manufacturing process, a bead morphology prediction model with high precision for ideal deposition of every pass was established. Design/methodology/approach The dynamic response of the process parameters on the bead width and bead height of cold metal transfer (CMT)-based AM was analyzed. A laser profile scanner was used to continuously capture the morphology variation. A prediction model of the deposition bead morphology was established using response surface optimization. Moreover, the validity of the model was examined using 15 groups of quadratic regression analyzes. Findings The relative errors of the predicted bead width and height were all less than 5% compared with the experimental measurements. The model was then preliminarily used with necessary modifications, such as further considering the interlayer process parameters, to guide the fabrication of complex three-dimensional components. Originality/value The morphology prediction of WAAMed bead is a critical issue. Most research has focused on the formability and defects in CMT-based WAAM and little research on the effect of process parameters on the morphology of the deposited layer in CMT-based WAAM has been conducted. To test the sensitivities of the processing parameters to bead size, the dynamic response of key parameters was investigated. A regression model was established to guide the process parameter optimization for subsequent multi-layer or component deposition.

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Pore formation and evolution in wire + arc additively manufactured 2319 Al alloy

Cited by 46 publications

References 37 publications

Microstructure Evolution and Mechanical Properties of a Wire-Arc Additive Manufactured Austenitic Stainless Steel: Effect of Processing Parameter

Microstructure Evolution and Mechanical Properties of a Wire-Arc Additive Manufactured Austenitic Stainless Steel: Effect of Processing Parameter

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

A model of bead size based on the dynamic response of CMT-based wire and arc additive manufacturing process parameters

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