Three-dimensional numerical simulation of arc and metal transport in arc welding based additive manufacturing

Zhou, Xiaosheng; Zhang, Haiou; Wang, Guilan; Bai, Xingwang

doi:10.1016/j.ijheatmasstransfer.2016.06.084

Cited by 87 publications

(23 citation statements)

References 39 publications

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“…For most metal materials, coarse primary columnar grains are formed in the WAAM process [12][13], there is a big demand for a microstructure control method. Recently, the authors [14] developed a three-dimensional numerical model of an electric arc based on magnetic fluid dynamics for arc based additive forming process with pure argon shielding gas. The influence of base surface topographies on the deposited bead shape and the heat and mass transfer of electric arc were investigated in detail.…”

Section: Introductionmentioning

confidence: 99%

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Bai

Colegrove

Ding

et al. 2018

International Journal of Heat and Mass Transfer

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207

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A three-dimensional numerical model has been developed to investigate the fluid flow and heat transfer behaviors in multilayer deposition of plasma arc welding (PAW) based wire and arc additive manufacture (WAAM). The volume of fluid (VOF) and porosity enthalpy methods are employed to track the molten pool free surface and solidification front, respectively. A modified double ellipsoidal heat source model is utilized to ensure constant arc heat input in calculation in the case that molten pool surface dynamically changes. Transient simulations were conducted for the 1 st , 2 nd and 21 st layer depositions. The shape and size of deposited bead and weld pool were predicted and compared with experimental results. The results show that for each layer of deposition the Marangoni force plays the most important role in affecting fluid flow, conduction is the dominant method of heat dissipation compared to convection and radiation to the air. As the layer number increases, the length and width of molten pool and the width of deposited bead increase, whilst the layer height decreases. However these dimensions remain constant when the deposited part is sufficiently high. In high layer deposition, where side support is absent, the depth of the molten pool at the rear part is almost flat in the Y direction. The profile of the deposited bead is mainly determined by static pressure caused by gravity and surface tension pressure, therefore the bead profile is nearly circular. The simulated profiles and size dimensions of deposited bead and molten pool were validated with experimental weld appearance, cross-sectional images and process camera images. The simulated results are in good agreement with experimental results.

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Section: Introductionmentioning

confidence: 99%

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Bai

Colegrove

Ding

et al. 2018

International Journal of Heat and Mass Transfer

Self Cite

207

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“…The finite element software package, ABAQUS (Palo Alto, CA, USA) was used for the thermal model in this research. Early study indicated that the temperature field of the arc would be disturbed by previous deposition in overlapping deposition process, which leads to the asymmetric distribution of the temperature field of the thermal model ( Figure 4 a,b) [ 13 ]. Therefore, the whole material was modelled to accurately reflect the influence of thermal cycle on the deposition block in this study.…”

Section: Methodsmentioning

confidence: 99%

Effect of Molten Pool Size on Microstructure and Tensile Properties of Wire Arc Additive Manufacturing of Ti-6Al-4V Alloy

Liu

et al. 2017

Materials

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Wire arc additive manufacturing (WAAM) technique is a cost-competitive and efficient technology to produce large structure components in industry domains. Mechanical properties are mainly dominated by the microstructure of the components, which is deeply affected by the molten pool size. In this work, to investigate the effect of the molten pool size on microstructure and mechanical properties of the components, a series of Ti-6Al-4V alloy blocks with different width of molten pool (WMP) ranging from 7 mm to 22 mm were deposited by adjusting the wire feed speed (WFS) from 100 cm/min to 500 cm/min. It is interesting to find that the macrostructure changes from columnar grains to equiaxial grains, and then returns to large columnar grains with the increase of WMP, which is mainly caused by the different cooling rates and thermal gradients. Nonetheless, the tensile properties of the components have a tendency to decline with the increase of WMP.

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“…A weak coupling model has been developed and veri ed in the author's previous research [19,22] , so it will not be described in detail in this article. In this study, the weak coupling model is applied to simulate the arc and metal transport in AWAM process assisted by ELSMF.…”

Section: Numerical Modelsmentioning

confidence: 99%

“…In Bai's model, the arc was supposed to be solid and the electromagnetic force was calculated by the nite element method. In our previous studies, Zhou, et al [19] , developed a three-dimensional weak coupling modeling method of the arc and metal transport to simulate the arc, molten pool dynamic and droplet impingement in arc welding based additive manufacturing, and veri ed the stability of this weak coupling modeling method to simulating the complex heat and mass transfer phenomena in arc welding based additive manufacturing. Compared with the uni ed model and separated model, a threedimensional weak coupling model has superior accuracy and lower computational consumption.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation of Arc and Metal Transfer in Arc Welding Based Additive Manufacturing Assisted by External Longitudinal Static Magnetic Field

Zhou¹,

Lian²,

Wang³

et al. 2020

Preprint

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The surface quality is one of important quality factors for arc welding based additive manufacturing (AWAM) parts. In this study, AWAM process assisted by an external longitudinal static magnetic field (ELSMF) is applied to improve surface quality of AWAM parts. In order to study the internal mechanism of AWAM process assisted by an external longitudinal magnetic field, a three-dimensional weak coupling model of the arc and metal transport is developed to simulate the arc, molten pool dynamic in AWAM assisted by ELSMF. The simulated results of single-bead deposition show that the ELSMF induces the asymmetrical tangential electromagnetic stirring in arc and molten pool, which can increase molten pool dynamics, drive the molten metal moving to the edge of the molten pool and reduce the temperature gradient. The simulated results of overlapping deposition show that the asymmetrical tangential electromagnetic stirring force can drive the molten metal moving to valley area between overlapping beads, which is beneficial to filling the valley area and improving the surface quality of the AWAM parts. The single-bead deposition experiment shows that the applying of ELSMF can reduce the height as well as increase the width of single weld bead. The multi-bead overlapping and the multi-layer multi-pass deposition experiments demonstrate that the external magnetic field can improve the surface quality of multi-layer part. The conclusions of the above study can provide the reference for AWAM process assisted by magnetic field.

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Three-dimensional numerical simulation of arc and metal transport in arc welding based additive manufacturing

Cited by 87 publications

References 39 publications

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

Effect of Molten Pool Size on Microstructure and Tensile Properties of Wire Arc Additive Manufacturing of Ti-6Al-4V Alloy

Numerical Simulation of Arc and Metal Transfer in Arc Welding Based Additive Manufacturing Assisted by External Longitudinal Static Magnetic Field

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