Rapid prototyping of 4043 Al-alloy parts by cold metal transfer

Nie, Yunpeng; Zhang, Peilei; Wu, Xi; Li, Guojin; Yan, Hua; Yu, Zhishui

doi:10.1080/13621718.2018.1438236

Cited by 49 publications

(24 citation statements)

References 17 publications

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“…When studying the deposition of an Al-Cu alloy, Cong et al (2015) showed that the CMT advanced process led to lower porosity levels if compared with the other CMT variants. Nie et al (2018) found relatively good mechanical properties and no anisotropy between the vertical and horizontal deposition directions with an ER4043 wire (Al-Si). By using different CMT variants to deposit Al-6Mg walls, Zhang et al (2018) found a finer microstructure and a more random grain distribution with the CMT advanced process.…”

Section: Introductionmentioning

confidence: 95%

Effect of the CMT advanced process combined with an active cooling technique on macro and microstructural aspects of aluminum WAAM

Teixeira

Scotti

Reis

et al. 2021

RPJ

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Purpose This paper aims to assess the combined effect of the Cold Metal Transfer (CMT) advanced process and of a thermal management technique (near immersion active cooling [NIAC]) on the macro and microstructure of Al wall-like preforms built by wire arc additive manufacturing (WAAM). As specific objective, it sought to provide information on the effects of the electrode-positive/electrode-negative (EP/EN) parameter in the CMT advanced process fundamental characteristics. Design/methodology/approach Initially, bead-on-plate deposits were produced with different EP/EN ratios, still keeping the same deposition rate, and the outcomes on the electrical signal traces and bead formation were analyzed. In a second stage, the EP/EN parameter and the layer edge to water distance (LEWD) parameter from the NIAC technique were systematically varied and the resultant macro and microstructures compared with those formed by applying natural cooling. Findings Constraints of EP/EN setting range were uncovered and discussed. The use of the NIAC technique favors the formation of finer grains. For a given EP/EN value, a variation in the NIAC intensity (LEWD value) showed marginal effect on grain size. When the EP/EN parameter effect is isolated, i.e. for a given LEWD setting, it was observed that an increase in the EP/EN level favors coarser grains. Originality/value Both the EP/EN parameter and the use of an active cooling technique (NIAC) might be used, even in combination, as effective tools for achieving proper macro and microstructure in WAAM of thin wall builds.

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Section: Introductionmentioning

confidence: 95%

Effect of the CMT advanced process combined with an active cooling technique on macro and microstructural aspects of aluminum WAAM

Teixeira

Scotti

Reis

et al. 2021

RPJ

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“…The post-processing involves machining of the Fig. 1 Development of wire arc additive manufacturing ( Ref 12,13,[38][39][40][41][42][43][44][45][46][47] product to achieve better surface finish. Sometimes, the heat treatment of the final product is also needed to get the desired material properties.…”

Section: Steps Involved In Waammentioning

confidence: 99%

Wire Arc Additive Manufacturing: A Comprehensive Review and Research Directions

Raut

Taiwade

2021

J. of Materi Eng and Perform

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Over the past years, the demand for the wire arc additive manufacturing (WAAM) is potentially increased, and it has become a promising alternative to subtractive manufacturing. Research reported that the wire arc additively manufactured (WAAMed) materialÕs mechanical properties are comparable to wrought or cast material. In comparison with other fusion sources, WAAM offers a significant cost saving and a higher deposition rate. However, there are significant challenges associated with WAAM such as undesirable microstructures and mechanical properties, high residual stresses, and distortion. Thus, more research is still needed to handle the above challenges by optimizing the process parameters and post-deposition heat treatment. In line with the above, this paper attempts to fill the gap by presenting a comprehensive review of WAAM literature including stagewise development of WAAM, metals and alloys used, effects of process parameters, methodologies used by various researchers to improve the quality of WAAM component. Besides, this work proposes the areas that could be used as avenues for future research.

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“…During the short circuit transition, the CMT welding technology can pull the droplet through the wire pulling back to overcome the surface tension of the droplet and avoid droplet rejection and necking burst [ 20 , 21 ]. Compared with other welding technologies using arc as the heat source, CMT welding technology has the characteristics of low heat input and no spatter as well as good forming quality, and has received extensive attention in recent years [ 22 , 23 , 24 ]. Cong B [ 25 ] utilized WAAM-CMT technology to manufacture Al-6.3%Cu alloys to investigate the application potential of aluminum alloys.…”

Section: Introductionmentioning

confidence: 99%

Microstructures and Properties of Al-Mg Alloys Manufactured by WAAM-CMT

Liu

Zhou

et al. 2022

Materials

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A wire arc additive manufacturing system, based on cold metal transfer technology, was utilized to manufacture the Al-Mg alloy walls. ER5556 wire was used as the filler metal to deposit Al-Mg alloys layer by layer. Based on the orthogonal experiments, the process parameters of the welding current, welding speed and gas flow, as well as interlayer residence time, were adjusted to investigate the microstructure, phase composition and crystal orientation as well as material properties of Al-Mg alloyed additive. The results show that the grain size of Al-Mg alloyed additive becomes smaller with the decrease of welding current or increased welding speed. It is easier to obtain the additive parts with better grain uniformity with the increase of gas flow or interlayer residence time. The phase composition of Al-Mg alloyed additive consists of α-Al matrix and γ (Al12Mg17) phase. The eutectic reaction occurs during the additive manufacturing process, and the liquefying film is formed on the α-Al matrix and coated on the γ phase surface. The crystal grows preferentially along the <111> and <101> orientations. When the welding current is 90 A, the welding speed is 700 mm/min, the gas flow is 22.5 L/min and the interlayer residence time is 5 min, the Al-Mg alloy additive obtains the highest tensile strength. Under the optimal process parameters, the average grain size of Al-Mg alloyed additive is 25 μm, the transverse tensile strength reaches 382 MPa, the impact absorption energy is 26 J, and the corrosion current density is 3.485 × 10−6 A·cm-2. Both tensile and impact fracture modes of Al-Mg alloyed additive are ductile fractures. From the current view, the Al-Mg alloys manufactured by WAAM-CMT have a better performance than those produced by the traditional casting process.

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Rapid prototyping of 4043 Al-alloy parts by cold metal transfer

Cited by 49 publications

References 17 publications

Effect of the CMT advanced process combined with an active cooling technique on macro and microstructural aspects of aluminum WAAM

Effect of the CMT advanced process combined with an active cooling technique on macro and microstructural aspects of aluminum WAAM

Wire Arc Additive Manufacturing: A Comprehensive Review and Research Directions

Microstructures and Properties of Al-Mg Alloys Manufactured by WAAM-CMT

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