Wire-arc additive manufacturing of nickel aluminum bronze/stainless steel hybrid parts – Interfacial characterization, prospects, and problems

Dharmendra, C.; Shakerin, Sajad; Ram, G.D. Janaki; Mohammadi, Mohsen

doi:10.1016/j.mtla.2020.100834

Cited by 66 publications

(26 citation statements)

References 24 publications

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“…Due to large thermal gradients and a larger density of geometrical dislocations in the WAAM process. Dharmendra et al [86] analyzed the hybrid component of nickel aluminium bronze and 316L stainless steel fabricated by GMAW based WAAM process, shown in Fig. 23a.…”

Section: Waam Processed Aluminium Alloysmentioning

confidence: 99%

“…The more considerable amount of dissolved Zn and Mg atoms into the Al matrix after T6 heat treatment, the effect of solid solution strengthening, causes an increase in tensile strength and plasticity reduction. Liu [86]. Reproduced with permission from Elsevier et al [88] analysed the microstructure and material properties of 2219 aluminium alloy deposited by double electrode gas metal arc (DE-GMA) based AM process.…”

Section: Waam Processed Aluminium Alloysmentioning

confidence: 99%

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Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Kumar

Manikandan

2021

Met. Mater. Int.

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Wire arc additive manufacturing (WAAM) technique became an emerging manufacturing technology because of its costeffective in creating large-scale metal parts with moderately high deposition rates. Mainly, WAAM works through the utilization of heat source as an electric arc by melting the metal wire to build the three-dimensional metal parts in a layer-by-layer approach, which may significantly minimize the fabrication costs compared to powder and other additive manufacturing techniques such as laser and electron beam, similarly. This article reviews WAAM processes and methods and gives an exhaustive overview of the residual stresses, microstructures, and material properties of the as-fabricated and post-fabrication treated WAAM components. The typical defects during the fabrication of metal components by the WAAM process are residual stresses, deformity, porosity, and cracking. And also, methods on controlling residual stresses, improving material properties, and effects of post-processing treatments to enhance the part quality fabricated by using the WAAM process are recommended in this review. Finally, the measurement methods of residual stresses in the metal parts and FEA simulations in the WAAM are discussed. FEA simulations provide better insights on moving heat source model, temperature distributions, and residual stresses in the WAAM process. This article concludes that selecting process parameters affects the quality WAAM component during the deposition process. And also, approaches to improving the part quality are proposed. The materials fabrication issues in the WAAM processes were outlined, and the advanced WAMM processes were suggested to obtain high quality and defect-free WAAM parts.

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Section: Waam Processed Aluminium Alloysmentioning

confidence: 99%

Section: Waam Processed Aluminium Alloysmentioning

confidence: 99%

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Kumar

Manikandan

2021

Met. Mater. Int.

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“…Critical analysis of the literature sources devoted to DED allows one to conclude that heat input is a crucial factor that determined the structural evolution and mechanical and functional characteristics of as-deposited metals such as Inconel 625 [3], Al-7Si-0.6Mg [4], Al-Mg alloys [5], Ti6Al4V [6], 2209 duplex stainless steel [7], and aluminum bronze [8][9][10]. In selective laser melting (SLM), the decisive role of the heat input was studied on alloys as follows: the Inconel 718 [11], Ti6Al4V alloy [12], AISI 316 stainless steel and AlSi10Mg alloys [13].…”

Section: Introductionmentioning

confidence: 99%

Heat Input Effect on Microstructure and Mechanical Properties of Electron Beam Additive Manufactured (EBAM) Cu-7.5wt.%Al Bronze

et al. 2021

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Electron beam additive wire-feed deposition of Cu-7.5wt.%Al bronze on a stainless-steel substrate has been carried out at heat input levels 0.21, 0.255, and 0.3 kJ/mm. The microstructures formed at 0.21 kJ/mm were characterized by the presence of both zigzagged columnar and small equiaxed grains with 10% of Σ3 annealing twin grain boundaries. No equiaxed grains were found in samples obtained at 0.255 and 0.3 kJ/mm. The zigzagged columnar ones were only retained in samples obtained at 0.255 kJ/mm. The fraction of Σ3 boundaries reduced at higher heat input values to 7 and 4%, respectively. The maximum tensile strength was achieved on samples obtained with 0.21 kJ/mm as tested with a tensile axis perpendicular to the deposited wall’s height. More than 100% elongation-to-fracture was achieved when testing the samples obtained at 0.3 kJ/mm (as tested with a tensile axis coinciding with the wall’s height).

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“…https://doi.org/10.1080/21663831. 2021.1958947 (HM) technology has been developed [5][6][7]. The forgingadditive HM manufactures the large and regular parts of a component through traditional forging and then manufactures the geometrically complex and small parts of the component through AM.…”

Section: Introductionmentioning

confidence: 99%

“…HMed parts often exhibited a strength mismatch among the substrate, AMed zone, and the bonding zone (BZ) [9]. And their unsatisfying plasticity was caused by the complexity and variability of the microstructure in the BZ [7]. How the heterogeneous microstructure forms in the BZ and whether it is able to be tailored have not been clarified.…”

Section: Introductionmentioning

confidence: 99%

Heterogeneous microstructure of the bonding zone and its dependence on preheating in hybrid manufactured Ti-6Al-4V

Zhang

et al. 2021

Materials Research Letters

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Hybrid manufacturing (HM) Ti-6Al-4V components combining the advantages of forging and additive manufacturing were achieved. The bonding zone of the HMed component joins the substrate and the additive manufactured zone and its α -α/α /α m -α/β heterogeneous microstructure was attributed to the distinguishing cooling rate and pseudo-isothermal annealing temperature. The phase transformation mechanisms were clarified with a numerical simulation model for thermal analysis. Moreover, preheating manipulate the size, volume fraction and distribution of α /α m /α phases to tailor the heterogeneous microstructure. IMPACT STATEMENTPreheating can serve as an effective way to tailor the heterogeneous microstructure in the bonding zone of HMed Ti-6Al-4V by affecting the cooling rate and pseudo-isothermal annealing temperature.

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Wire-arc additive manufacturing of nickel aluminum bronze/stainless steel hybrid parts – Interfacial characterization, prospects, and problems

Cited by 66 publications

References 24 publications

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Assessment of Process, Parameters, Residual Stress Mitigation, Post Treatments and Finite Element Analysis Simulations of Wire Arc Additive Manufacturing Technique

Heat Input Effect on Microstructure and Mechanical Properties of Electron Beam Additive Manufactured (EBAM) Cu-7.5wt.%Al Bronze

Heterogeneous microstructure of the bonding zone and its dependence on preheating in hybrid manufactured Ti-6Al-4V

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