Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Graf, Marcel; Hälsig, André; Höfer, Kevin; Awiszus, Birgit; Mayr, P.

doi:10.3390/met8121009

Cited by 71 publications

(34 citation statements)

References 16 publications

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“…Each printed wall consisted of 15 layers on the substrate, which was made from commercially-pure aluminum bars (190 mm × 50 mm × 6 mm). Each layer was deposited in an inverse direction, i.e., bi-directionally, to maintain higher uniformity of the wall dimensions at both wall ends, as already demonstrated in the literature (for instance, by Graf et al [17]). Substrate bucking and uneven heat concentration during the deposition would interfere in the layer formation, impairing the comparisons.…”

Section: Methodology and Methodsmentioning

confidence: 99%

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Yehorov

Silva

Scotti

2019

JMMP

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The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.

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Section: Methodology and Methodsmentioning

confidence: 99%

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Yehorov

Silva

Scotti

2019

JMMP

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“…4. FE model with the mesh -base plate 32.000 FEs, each la e 32.000 FEs, each lay yer 15.000 FEs er 15.000 FEs Temperature-dependent physical properties of welding wire (G3Si1), used in numerical computation, are taken from [2] because of the similarity in the chemical composition of G3Si1 and G4Si1 material, used in [2]. Same properties were used for the base plate.…”

Section: Experimental Case Stud Experimental Case Study Ymentioning

confidence: 99%

“…Because the process itself involves thermo-mechanically complex phenomena, Finite Element-based virtual models are commonly employed to optimize the process parameters [1]. The finite elements (FEs) activation is applied in numerical investigations of deposition of a welding wire, where the melting temperature is employed as the activation criterion [2]. There are two procedures available for dealing with inactivating FEs in the FE numerical model [3].…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Advanced computational modelling of metallic wire-arc additive manufacturing

Kovšca¹,

Starman²,

Ščetinec³

et al. 2021

Esaform 2021

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Wire-arc welding-based additive manufacturing (WAAM) is a 3D printing technology for production of near-net-shape parts with complex geometry. This printing technology enables to build up a required shape layer by layer with a deposition of a consumable welding wire, where the welding arc is a source of heat. Welding is usually performed by CNC-controlled robotic manipulator, which provides a controlled location of material layer adding. Because the process itself involves thermo-mechanically complex phenomena, Finite Element-based virtual models are commonly employed to optimize the process parameters. This paper presents advanced computational modelling of the WAAM of a tube. A thermo-mechanical numerical model of the process is calibrated against experimental data, measured as temperature variation at the acquisition point. The virtual modelling starts with a preparation of the tube geometry in CAD software, where the geometry of the single-layer cross-section is assumed. The geometry is then exported to a G-code format data file and used to control robotic manipulator motion. On the other side, the code serves as an input to in-house developed code for automatic FEs activation in the simulation of the material layer-adding process. The time of activation of the finite elements (FEs) is directly related to the material deposition rate. The activation of the FEs is followed by a heat source, modeled with a double ellipsoidal power density distribution. The thermo-mechanical problem was solved as uncoupled to speed-up computation.

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“…2(a). These parameters were determined from results reported by Nuraini et al [13] Table 2: The values for heat source parameters [13] The heat source model considers the heat flux losses by convection and radiation; thus, during the FE analysis, a convection heat transfer coefficient of 35 W/m 2 K, the radiative emissivity of 0.5, and the Stefan-Boltzmann constant of 5.67x10 -8 W m -2 K -4 were used for the external sides of the substrate and layers [14]. The parameters for heat loss were not applied to the longitudinal mid-plane because of the symmetry thermal boundary.…”

Section: Simulation Proceduresmentioning

confidence: 99%

Study on the thermal cycle of Wire Arc Additive Manufactured (WAAM) carbon steel wall using numerical simulation

Saadatmand

Talemi

2020

Frattura Ed Integrità Strutturale

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The thermal behavior in WAAM process is a significant cause for thermal stress. In this paper, a 3D model of a four-layer wall is built in ABAQUS software in order to investigate the thermal behavior in a carbon steel (ASTM A36) WAAM wall. Moreover, the effects of substrate preheating temperature and travel speed on the temperature distribution are studied. The modelling results show that with increase in number of deposited layers, the peak temperature increases but average cooling speed decreases. Furthermore, substrate preheating increases peak temperature of fist layer and decreases its average cooling speed. Regarding simulation results, the travel speed has major effects on the thermal behavior of deposited layers.

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Thermo-Mechanical Modelling of Wire-Arc Additive Manufacturing (WAAM) of Semi-Finished Products

Cited by 71 publications

References 16 publications

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

Advanced computational modelling of metallic wire-arc additive manufacturing

Study on the thermal cycle of Wire Arc Additive Manufactured (WAAM) carbon steel wall using numerical simulation

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