Semi-solid wire-feed additive manufacturing of AlSi7Mg by direct induction heating

Englert, Lukas; Klumpp, Alexander; Ausländer, Antonia; Schulze, Volker; Dietrich, Stefan

doi:10.1016/j.addlet.2022.100067

Cited by 15 publications

(7 citation statements)

References 17 publications

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“…In contrast, a high liquid fraction of semi-solid metal would reduce the quality of formed parts because of less control of depositing material during material deposition. Further, Englert et al 52 have explained the importance of liquid fraction during semi-solid AM of aluminum material and explained that varying the temperature leads to changes in the microstructure of the printed samples. Chen et al 53 explained the importance of microstructure and explained that large dendrite structure formation in feedstock material would clog the extruder.…”

Section: Resultsmentioning

confidence: 99%

Effect of standoff distance on printability of aluminum 5356 alloy through extrusion-based metal additive manufacturing using induction heating

Choubey,

Jain

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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Induction heating as a heat source in extrusion-based metal additive manufacturing (EMAM) is gaining popularity due to its inherent benefits as a safe, clean, and precise heating source. Metal wire as a feedstock material is economically viable and highly efficient in terms of material utilization compared to powder feedstock materials. The combination of induction heating with metal wire as a feedstock through an EMAM system has been investigated in this article. The article aims to identify the standoff distance for printing aluminum 5356 in EMAM using induction heating ( Figure 1 ). In induction heating-based AM, it is crucial to identify the standoff distance between the extruder and substrate to maintain a constant extruder tip temperature and ensure a consistent liquid/solid fraction ratio for uniform material deposition. The approach adopted in this article is to perform electromagnetic and thermal multifield coupling model simulations of extruder with the substrate through a two-dimensional axe-symmetrical model using COMSOL multiphysics. The simulation model analyzed the extruder tip temperature at variable standoff distance cases during extruder heating and material deposition processes. A practical approach for thermal cartography has been used to identify extruder tip temperature during experimentation using an infrared imager. The extruder tip temperature results obtained through simulation have been compared with experimental results and found to be in close agreement with each other. A favorable temperature range of 575–625 °C is obtained through a standoff distance of 2.0 mm compared to other standoff distances taken for the study.

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Section: Resultsmentioning

confidence: 99%

Effect of standoff distance on printability of aluminum 5356 alloy through extrusion-based metal additive manufacturing using induction heating

Choubey,

Jain

2023

Proceedings of the Institution of Mechanical Engineers, Part L:

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show abstract

“…Finding a stable process window resulted in the generation of four-layer structures [20]. Englert [21] and colleagues use an approach to inductively heat an aluminum wire without using a nozzle to conduct thermal energy. In this process, the wire is directly heated, but not completely melted.…”

Section: Introductionmentioning

confidence: 99%

Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power

Kimme,

Gruner,

Hälsig

et al. 2024

Preprint

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Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing regular droplet formation and uniform size and shape when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and overall efficiency.

show abstract

“…Finding a stable process window resulted in the generation of four-layer structures [20]. Englert [21] and colleagues used an approach to inductively heat an aluminum wire without using a nozzle to conduct thermal energy. In this process, the wire is directly heated, but not completely melted; rather, it is heated to a temperature within the melting interval by a single-winding inductor.…”

Section: Introductionmentioning

confidence: 99%

Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power

Kimme,

Gruner,

Hälsig

et al. 2024

JMMP

View full text Add to dashboard Cite

Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits a sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing a regular droplet formation of 14 Hz and uniform shapes and sizes between 2.11 and 2.65 mm in diameter when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and indicate an overall efficiency of approximately 10%.

show abstract

Semi-solid wire-feed additive manufacturing of AlSi7Mg by direct induction heating

Cited by 15 publications

References 17 publications

Effect of standoff distance on printability of aluminum 5356 alloy through extrusion-based metal additive manufacturing using induction heating

Effect of standoff distance on printability of aluminum 5356 alloy through extrusion-based metal additive manufacturing using induction heating

Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power

Droplet Formation and Energy Input during Induction Wire Melting with Pulsed and Constant Generator Power

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