Wire Arc Additive Manufacturing (WAAM) process of nickel based superalloys – A review

Dhinakaran, V.; Ajith, J.; Fahmidha, A. Fathima Yasin; Jagadeesha, T.; Sathish, T.; Stalin, B.

doi:10.1016/j.matpr.2019.08.159

Cited by 164 publications

(25 citation statements)

References 7 publications

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“…LDM, WAAM) are also suitable for the production of AM components. Numerous metallic materials can be used, such as steels [2][3][4], aluminium materials [5][6][7] and nickel-based alloys [8][9][10]. Titanium and its alloys are of particular interest, especially to the aerospace industry, due to their excellent properties, including their high strength to density ratio and their resistance to corrosive environments [11].…”

Section: Introductionmentioning

confidence: 99%

Contactless temperature measurement in wire-based electron beam additive manufacturing Ti-6Al-4V

et al. 2021

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The complex thermal cycles and temperature distributions observed in additive manufacturing (AM) are of particular interest as these define the microstructure and the associated properties of the part being built. Due to the intrinsic, layer-by-layer material stacking performed, contact methods to measure temperature are not suitable, and contactless methods need to be considered. Contactless infrared irradiation techniques were applied by carrying out thermal imaging and point measurement methods using pyrometers to determine the spatial and temporal temperature distribution in wire-based electron beam AM. Due to the vacuum, additional challenges such as element evaporation must be overcome and additional shielding measures were taken to avoid interference with the contactless techniques. The emissivities were calibrated by thermocouple readings and geometric boundary conditions. Thermal cycles and temperature profiles were recorded during deposition; the temperature gradients are described and the associated temperature transients are derived. In the temperature range of the α+β field, the cooling rates fall within the range of 180 to 350 °C/s, and the microstructural characterisation indicates an associated expected transformation of β→α'+α with corresponding cooling rates. Fine acicular α and α’ formed and local misorientation was observed within α as a result of the temperature gradient and the formation of the α’.

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Section: Introductionmentioning

confidence: 99%

Contactless temperature measurement in wire-based electron beam additive manufacturing Ti-6Al-4V

et al. 2021

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“…In recent years, this technology has been used for the fabrication of high-performance parts in aerospace industry or the energy sector. Therefore, materials such as titanium alloys [8,9] or nickel-base alloys [10,11] have gained increasing interest in the last years. The development of cost efficient production systems [12] with high deposition rates makes this technology accessible for industries such as architecture or construction engineering.…”

Section: Introduction and State Of The Artmentioning

confidence: 99%

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

et al. 2020

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Wire arc additive manufacturing (WAAM) by gas metal arc welding (GMAW) is a suitable option for the production of large volume metal parts. The main challenge is the high and periodic heat input of the arc on the generated layers, which directly affects geometrical features of the layers such as height and width as well as metallurgical properties such as grain size, solidification or material hardness. Therefore, processing with reduced energy input is necessary. This can be implemented with short arc welding regimes and respectively energy reduced welding processes. A highly efficient strategy for further energy reduction is the adjustment of contact tube to work piece distance (CTWD) during the welding process. Based on the current controlled GMAW process an increase of CTWD leads to a reduction of the welding current due to increased resistivity in the extended electrode and constant voltage of the power source. This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel. Thereby, an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.

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“…Hence, the applications of wire-feed DED can be found in the aerospace industry, e.g., mount rings for entire fan cases [3] and features of compressor casings [4] of turbo jet engines as well as space rocket nozzles [5]. Thus, an increased interest in the use of the wire-feed DED for processing of high temperature and corrosion resistant metals, like stainless steels [6][7][8], Nickel [8][9][10][11] and Titanium-based [12,13] alloys, is being observed.…”

Section: Introductionmentioning

confidence: 99%

Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire

Kisielewicz

Pandian

Sthen

et al. 2021

Metals

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This study investigates the influence of resistive pre-heating of the feedstock wire (here called hot-wire) on the stability of laser-directed energy deposition of Duplex stainless steel. Data acquired online during depositions as well as metallographic investigations revealed the process characteristic and its stability window. The online data, such as electrical signals in the pre-heating circuit and images captured from side-view of the process interaction zone gave insight on the metal transfer between the molten wire and the melt pool. The results show that the characteristics of the process, like laser-wire and wire-melt pool interaction, vary depending on the level of the wire pre-heating. In addition, application of two independent energy sources, laser beam and electrical power, allows fine-tuning of the heat input and increases penetration depth, with little influence on the height and width of the beads. This allows for better process stability as well as elimination of lack of fusion defects. Electrical signals measured in the hot-wire circuit indicate the process stability such that the resistive pre-heating can be used for in-process monitoring. The conclusion is that the resistive pre-heating gives additional means for controlling the stability and the heat input of the laser-directed energy deposition.

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Wire Arc Additive Manufacturing (WAAM) process of nickel based superalloys – A review

Cited by 164 publications

References 7 publications

Contactless temperature measurement in wire-based electron beam additive manufacturing Ti-6Al-4V

Contactless temperature measurement in wire-based electron beam additive manufacturing Ti-6Al-4V

Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW)

Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire

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