Selection of Optimal Process Parameters for Wire Arc Additive Manufacturing

Liberini, Mariacira; Astarita, Antonello; Campatelli, Gianni; Scippa, Antonio; Montevecchi, Filippo; Venturini, Giuseppe; Durante, Massimo; Boccarusso, Luca; Minutolo, F. Memola Capece; Squillace, Antonino

doi:10.1016/j.procir.2016.06.124

Cited by 133 publications

(50 citation statements)

References 9 publications

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“…This microstructure formation is due to the reheating and remelting effect induced by successive layer depositions and different cooling conditions in each zone. The microstructural characteristics of the built thinwalled component observed in this study are similar to those reported in the previous studies 18,20,21 . The microstructures of the built thin-walled parts could also be adjusted by using alternating cycles of cooling or rolling deposited layers 6 .…”

Section: Discussionsupporting

confidence: 90%

“…The reason is that the value of the thermal shock of the lower zone is higher with respect to the middle zone. The lower zone (including about 4 first deposited layers) contacts the cold substrate, while the middle zone contacts the warm deposited layer 18 . In addition, the middle zone presents a thermal gradient lower than that of the lower zone 19 .…”

Section: Resultsmentioning

confidence: 99%

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A preliminary study on gas metal arc welding-based additive manufacturing of metal parts

Le¹

2020

Sci. Tech. Dev. J.

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Introduction: In the past three decades, additive manufacturing (AM), also known as 3D printing, has emerged as a promising technology, which allows the manufacture of complex parts by adding material layer upon layer. In comparison, with other metal-based AM technologies, gas metal arc welding-based additive manufacturing (GMAW-based AM) presents a high deposition rate and has the potential for producing medium and large metal components. To validate the technological performance of such a manufacturing process, the internal quality of manufactured parts needs to be analyzed, particularly in the cases of manufacturing the parts working in a critical load-bearing condition. Therefore, this paper aims at investigating the internal quality (i.e., and mechanical properties) of components manufactured by the GMAW-based AM technology. Method: A gas metal arc welding robot was used to build a thin-walled component made of mild steel on a low-carbon substrate according to the AM principle. Thereafter, the specimens for observing and mechanical properties were extracted from the built thin-walled component. The of the specimen were observed by an optical microscope; the hardness was measured by a digital tester, and the tensile tests were carried out on a tensile test machine. Results: The results show that the GMAW-based AM-built thin-walled components possess an adequate that varies from the top to the bottom of the built component: structures with primary dendrites in the upper zone; granular structure of with small regions of at grain boundaries in the middle zone, and grains of in the lower zone. The hardness (ranged between 164±3.46 HV to 192±3.81 HV), yield strength (YS offset of 0.2% ranged from 340±2 to 349.67±1.53 ), and ultimate tensile strength (UTS ranged from 429±1 to 477±2 ) of the GMAW-based AM-built components were comparable to those of wrought mild steel. Conclusions: The results obtained in this study demonstrate that the GMAW-based AM-built components possess adequate and good mechanical properties for real applications. This allows us to confirm the feasibility of using a conventional gas metal arc welding robot for additive manufacturing or repairing/re-manufacturing of metal components.

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Section: Discussionsupporting

confidence: 90%

Section: Resultsmentioning

confidence: 99%

A preliminary study on gas metal arc welding-based additive manufacturing of metal parts

Le¹

2020

Sci. Tech. Dev. J.

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show abstract

“…Furthermore, efficiencies of the MAM processes can be calculated as in [19], which can contribute to a greater understanding of the resultant metallurgical properties of various build parameters. Previous studies [9,20,21] show the importance of controlling and utilizing net heat input for additive manufacturing, particularly for modeling and simulation. Heat input is known as the amount of energy that is transferred to the base metal by a source of energy per unit of weld length.…”

Section: Design Of Experiments For Repeatable Resultsmentioning

confidence: 99%

Processing Parameter DOE for 316L Using Directed Energy Deposition

Sciammarella

Najafabadi

2018

JMMP

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Abstract:The ability to produce consistent material properties across a single or series of platforms, particularly over time, is the major objective in metal additive manufacturing (MAM) research. If this can be achieved, it will result in widespread adoption of the technology for industry and place it into mainstream manufacturing. However, before this can happen, it is critical to develop an understanding of how processing parameters influence the thermal conditions which dictate the mechanical properties of MAM builds. Research work reported in the literature of MAM is generally based on a set of parameters and/or the review of a few parameter changes, and observing the effects that these changes (i.e., microstructure, mechanical properties) have. While these articles provide results with some insight, there lacks a standard approach that can be used to allow meaningful comparisons and conclusions to be made concerning the optimization of the processing variables. This study provides a template which can be used for making comparisons across DED platforms.The tests are performed with a design of experiments (DOE) philosophy directed to evaluate the effect of selected parameters on the measured properties of the DED builds. Specifically, a laser engineering net shaping system (LENS) is used to build multilayered 316L coupons and analyze how build parameters such as laser power, travel speed, and powder feed rate influence the thermal conditions that will define both microstructure and microhardness. A fundamental conclusion of this research is that it is possible to repeatedly obtain a consistent microstructure that contains a fine cellular substructure with a low level of porosity (less than 1.1%) and with microhardness that is equal to or better than wrought 316L. This is mainly achieved by maintaining an associated powder flow to travel speed ratio at the power level, ensuring an appropriate net heat input for the build process.

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“…The most extended AM technologies (such as laser melting deposition (LMD) and selective laser melting (SLM)) are based on the fusion a metallic powder using a laser or an electron beam as a heating source. These processes can reach good dimensional accuracy, but the part size is limited by the low deposition rate (0.12-0.6 kg/h) [2]. To produce airframe parts of several meters economically, deposition rates of kilograms per hour are needed and this can be obtained by wire arc additive manufacturing (WAAM) [3].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts

Alonso

Veiga

Suárez

et al. 2019

Metals

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The manufacturing of titanium airframe parts involves significant machining and low buy-to-fly ratios. Production costs could be greatly reduced by the combination of an additive manufacturing (AM) process followed by a finishing machining operation. Among the different AM alternatives, wire arc additive manufacturing (WAAM) offers deposition rates of kg/h and could be the key for the production of parts of several meters economically. In this study, the influence of the manufacturing process of Ti6Al4V alloy on both its material properties and machinability is investigated. First, the mechanical properties of a workpiece obtained by WAAM were compared to those in a conventional laminated plate. Then, drilling tests were carried out in both materials. The results showed that WAAM leads to a higher hardness than laminated Ti6Al4V and satisfies the requirements of the standard in terms of mechanical properties. As a consequence, higher cutting forces, shorter chips, and lower burr height were observed for the workpieces produced by AM. Furthermore, a metallographic analysis of the chip cross-sectional area also showed that a serrated chip formation is also present during drilling of Ti6Al4V produced by WAAM. The gathered information can be used to improve the competitiveness of the manufacturing of aircraft structures in terms of production time and cost.

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Selection of Optimal Process Parameters for Wire Arc Additive Manufacturing

Cited by 133 publications

References 9 publications

A preliminary study on gas metal arc welding-based additive manufacturing of metal parts

A preliminary study on gas metal arc welding-based additive manufacturing of metal parts

Processing Parameter DOE for 316L Using Directed Energy Deposition

Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts

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