Thermal analysis of TIG-WAAM based metal deposition process using finite element method

Gokhale, Nitish P.; Kala, Prateek

doi:10.1016/j.matpr.2020.09.756

Cited by 13 publications

(3 citation statements)

References 18 publications

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“…Welding metals is a process that includes heating and cooling cycles, which strongly influences chemical-metallurgical reactions in liquid metal, phase transformations, grain growth, and therefore final material mechanical properties [12]. To better understand the mechanisms taking place during WAAM and to minimize the costs of experimental investigations at the same time, a simulation approach is eagerly applied, where not only finite element models [11,[13][14][15][16][17], but also neural networks [16,18,19] or mathematical [20], recursive models [21] are increasingly used. However, to accurately simulate the final properties of the part obtained by the WAAM process, a realistic heat source shape and distribution is necessary [22].…”

Section: Introductionmentioning

confidence: 99%

Determination of welding heat source parameters for fem simulation based on temperature history and real bead shape

Szyndler

2023

Materials Research Proceedings

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Abstract. To improve process understanding and increase the numerical prediction quality of a wire arc additive manufacturing (WAAM) process, this paper focuses on determining the parameters of a numerical model that reproduces an experimental setup of a welding process, with particular attention given to the actual shape of the weld bead. The dimensions of the heat source (HS) model in a welding process are determined based on experimentally measured weld pool sizes as well as temperature history at selected points below and adjacent to a weld seam. The whole experimental setup is accurately reproduced within the Simufact.Welding software and an optimization procedure is applied to obtain the best possible agreement between experimental and numerical results. A validated numerical model with reliable parameters for two heat sources is later used to predict and observe material behavior during the WAAM process of more complex parts.

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Section: Introductionmentioning

confidence: 99%

Determination of welding heat source parameters for fem simulation based on temperature history and real bead shape

Szyndler

2023

Materials Research Proceedings

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“…Compared with powder AM, using welding wire as the raw material for AM not only improves the material deposition efficiency [ 14 ] but also reduces the manufacturing cost. [ 15,16 ] However, the high‐quality production of many materials is limited by the high heat input, which leads to challenges in processing many of the materials involved in twin‐wire arc additive manufacturing (WAAM). [ 17 ] Notably, Huang et al [ 18 ] extended the structural analysis of WAAM by considering the thermal and mechanical properties inherent in direct energy deposition.…”

Section: Introductionmentioning

confidence: 99%

Heat Accumulation, Microstructure Evolution, and Stress Distribution of Ti–Al Alloy Manufactured by Twin‐Wire Plasma Arc Additive

Hou

Qian

et al. 2022

Adv Eng Mater

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Herein, the deposition of a Ti–Al(48 at%) alloy via twin‐wire arc additive manufacturing (WAAM) using plasma arc welding (PAW) and tungsten inert gas (TIG) welding arc sources is presented. The microstructure and the phase composition of different regions of the alloy are analyzed using metalloscopy and X‐ray diffraction. The transient temperature field and residual stress distribution are measured before and after the process, respectively. A transient thermostress model is established using the finite‐element method. Results show that the alloy is composed primarily of α2‐Ti3Al and γ‐TiAl phases, while the microstructure evolution during the Ti–Al(48 at%) alloy deposition process is described. The thermal conductivity in the lower region of the alloy far exceeds that in the middle and upper regions. The thermal conductivity is smaller in the upper region and the midregion, resulting in the increase in heat accumulation. Due to arc shrinkage and reduced heat input, the PAW process reduces the heat accumulation and stress distribution differences more effectively than the TIG process.

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“…Wu et al [23] established a finite element (FE) model to simulate the GTAW-based WAAM process of Ti6Al4V using active interlayer cooling with compressed CO 2 and explored cooling on thermal behaviour, geometric characteristics and deformation of the deposited alloy. Gokhale et al [24] created a FE model for the GTAW-based WAAM process model and analysed the influence of temperature distribution on metal deposition under path planning. Sun et al [25] analysed the distribution characteristics of residual stress in the WAAM components made of Al alloys by different welding methods.…”

Section: Introductionmentioning

confidence: 99%

Heat propagation simulation of thin-walled Ti6Al4V alloy components fabricated by double-wire GTAW additive manufacturing

Tian

et al. 2022

Science and Technology of Welding and Joining

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In this study, a temperature field finite element model of the thin-walled Ti6Al4V alloy component fabricated by double-wire tungsten arc welding-based wire arc additive manufacturing was established. Detailed heat propagation of the molten pool and the deposited layer was analysed systematically. The simulated results illustrate that the heat accumulation of the thin-walled Ti6Al4V alloy component becomes evident step by step as the deposition process proceeds. The height of the specified heat affect zone increases gradually, and then stabilises, and the stable value is ∼ 14 mm. The molten pool influences two deposition layers when it moves. The heat conduction from the thin-walled to the substrate still plays a major role as the layers are deposited.

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Thermal analysis of TIG-WAAM based metal deposition process using finite element method

Cited by 13 publications

References 18 publications

Determination of welding heat source parameters for fem simulation based on temperature history and real bead shape

Determination of welding heat source parameters for fem simulation based on temperature history and real bead shape

Heat Accumulation, Microstructure Evolution, and Stress Distribution of Ti–Al Alloy Manufactured by Twin‐Wire Plasma Arc Additive

Heat propagation simulation of thin-walled Ti6Al4V alloy components fabricated by double-wire GTAW additive manufacturing

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