Use of CMT-Surfacing for Additive Formation of Titanium Alloy Workpieces

Shchitsyn, Yu. D.; Krivonosova, E. A.; Трушников, Д. Н.; Ol’shanskaya, T. V.; Kartashov, M. F.; Неулыбин, С. Д.

doi:10.1007/s11015-020-00967-0

Cited by 8 publications

(4 citation statements)

References 10 publications

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“…Устранение пористости также оказывается дополнительным эффектом использования гибридных технологий аддитивного производства, в которых наплавленные слои линейного элемента изделия проковываются пневмомолотком или обкатываются роликом. Такие технологии в последние десять лет разрабатываются рядом научных организаций: университетами Крэнфилда и Манчестера [3,4], Индийским институтом технологии Бомбея [5], Пермским национальным исследовательским политехническим университетом [6][7][8][9], Брянским государственным техническим университетом [10,11].…”

Section: Introductionunclassified

Modeling of the Distribution of Residual Porosity of a Metal Product in Additive Manufacturing With Layer-by-Layer Forging

Keller,

Kazantsev,

Dudin

et al. 2022

PSP

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Porosity, which occurs in products made of aluminum-magnesium alloys synthesized by wire-arc surfacing, significantly worsens the characteristics of fatigue strength. The developed technology of hybrid additive manufacturing with layer-by-layer forging of each deposited layer of material is able to minimize the porosity of the product. To select the rational parameters of the technological process, the evolution of the porosity distribution over the cross-section of a linear element after its single forging with a pneumatic hammer is investigated. A numerical model of the process is constructed in the LS-DYNA® package, where the Gurson–Tvergaard–Needleman relations are taken as constitutive equations of plastic deformation of the material and porosity evolution. To determine the parameters of the Johnson–Cook hardening law, tests of the AMg6 alloy were performed in a wide range of strain rates. The impact of the pneumatic hammer in the numerical model was calibrated using an accelerometric and strain-gauged steel target, as well as by distortions of the cross-section of a forged bar made of AMg6 alloy. Calculations according to the model are compared with experimental data, for which two linear segments were made by additive manufacturing with and without layer-by-layer forging, from the cross-sections of which the slots processed for pore visualization were prepared. With this method of pressure treatment, the decrease in porosity in the boundary layer of the workpiece mainly depends on the accumulated plastic deformations and does weakly sensitive the appearance of a stressed state. The model allows you to predict the size of the area under the hammer head depending on the processing mode, within which the porosity is eliminated by forging. The use of such modes will ensure the manufacturing of products without residual porosity in the processes of additive manufacturing by surfacing with layer-by-layer forging.

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Section: Introductionunclassified

Modeling of the Distribution of Residual Porosity of a Metal Product in Additive Manufacturing With Layer-by-Layer Forging

Keller,

Kazantsev,

Dudin

et al. 2022

PSP

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“…Additive arc processes, which make it possible to synthesize large metal parts with a minimum allowance for machining and properties at the level of metals of traditional technologies, ensure significant savings of metal and reduce the costs of pre-production engineering [ 1 , 2 , 3 , 4 ]. This concerns the production of aluminum [ 5 , 6 ], titanium [ 7 , 8 , 9 , 10 ], and other light high-strength alloys.…”

Section: Introductionmentioning

confidence: 99%

“…Among the arc methods, CMT (cold metal transfer) is an updated version of consumable electrode welding in a shielded gas based on the mechanism of a controlled metal flow mode into the weld pool using pulsed current and reciprocating wire movement. It has a number of great advantages when it comes to additive technologies [ 9 ]. The wire reverse feed system is synchronized with a high-speed digital control that determines the arc length, short circuit phase, and heat transfer to the weld zone [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

“…It has a number of great advantages when it comes to additive technologies [ 9 ]. The wire reverse feed system is synchronized with a high-speed digital control that determines the arc length, short circuit phase, and heat transfer to the weld zone [ 9 ]. This process excludes metal splashing and ensures the stability of weld formation and minimal heat transfer to the processing area.…”

Section: Introductionmentioning

confidence: 99%

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Formation of Structure and Properties of Two-Phase Ti-6Al-4V Alloy during Cold Metal Transfer Additive Deposition with Interpass Forging

et al. 2021

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The paper deals with the main formation patterns of structure and properties of a titanium alloy of the Ti-6Al-4V system during additive manufacturing using cold metal transfer (CMT) wire deposition. The work aims to find the optimal conditions for layer-by-layer deposition, which provides the high physical and mechanical properties of the titanium alloy of the Ti-6Al-4V system hybrid, additively manufactured using CMT deposition. Particular attention is paid to interpass forging during the layered printing of the product. Additionally, we investigate how the heat treatment affects the structure and properties of the Ti-6Al-4V alloy that has been CMT-deposited, both with and without forging. These studies have shown that the hybrid multilayer arc deposition technology, with interpass strain hardening, allows the use of high temperature and high technology titanium alloys to obtain products of a required geometric shape. It has been proven that the interpass deformation effect during CMT deposition contributes to a significant decrease in the sizes of the primary β-grains. In addition, forging enhances the effect of microstructure refinement, which is associated with phase recrystallization in deformed areas. It is shown that the heat treatment leads not only to a change in the morphology of the phases but also to additional phase formations in the structure of the Ti-6Al-4V-deposited metal while the mechanism is realized and consists of the gradual decomposition of the martensitic α′-phase and the formation of a dispersive α2-phase. This structure formation process is accompanied by the dispersion hardening of the α-phase. The strength characteristics of the Ti-6Al-4V alloy obtained using layer-by-layer CMT with forging are given; they exceed the strength level of materials obtained with the traditional technologies of pressure treatment, and there is no decrease in plasticity characteristics. The use of the subsequent heat treatment makes it possible to increase the ductility characteristics of the deposited and forged Ti-6Al-4V material by 1.5–2 times without strength loss.

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Effect of Substrate Temperature on Structure Formation in Titanium Alloy during Direct Laser Deposition

Горунов

2020

Metallurgist

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Use of CMT-Surfacing for Additive Formation of Titanium Alloy Workpieces

Cited by 8 publications

References 10 publications

Modeling of the Distribution of Residual Porosity of a Metal Product in Additive Manufacturing With Layer-by-Layer Forging

Modeling of the Distribution of Residual Porosity of a Metal Product in Additive Manufacturing With Layer-by-Layer Forging

Formation of Structure and Properties of Two-Phase Ti-6Al-4V Alloy during Cold Metal Transfer Additive Deposition with Interpass Forging

Effect of Substrate Temperature on Structure Formation in Titanium Alloy during Direct Laser Deposition

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