Effect of the CMT advanced process combined with an active cooling technique on macro and microstructural aspects of aluminum WAAM

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Felipe Ribeiro Teixeira ◽  
Fernando Matos Scotti ◽  
Ruham Pablo Reis ◽  
Américo Scotti
Keyword(s):  
Electrical Signal ◽  
Management Technique ◽  
Marginal Effect ◽  
Thin Wall ◽  
Cold Metal Transfer ◽  
Content Type ◽  
Active Cooling ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing ◽  
Cooling Technique

Purpose This paper aims to assess the combined effect of the Cold Metal Transfer (CMT) advanced process and of a thermal management technique (near immersion active cooling [NIAC]) on the macro and microstructure of Al wall-like preforms built by wire arc additive manufacturing (WAAM). As specific objective, it sought to provide information on the effects of the electrode-positive/electrode-negative (EP/EN) parameter in the CMT advanced process fundamental characteristics. Design/methodology/approach Initially, bead-on-plate deposits were produced with different EP/EN ratios, still keeping the same deposition rate, and the outcomes on the electrical signal traces and bead formation were analyzed. In a second stage, the EP/EN parameter and the layer edge to water distance (LEWD) parameter from the NIAC technique were systematically varied and the resultant macro and microstructures compared with those formed by applying natural cooling. Findings Constraints of EP/EN setting range were uncovered and discussed. The use of the NIAC technique favors the formation of finer grains. For a given EP/EN value, a variation in the NIAC intensity (LEWD value) showed marginal effect on grain size. When the EP/EN parameter effect is isolated, i.e. for a given LEWD setting, it was observed that an increase in the EP/EN level favors coarser grains. Originality/value Both the EP/EN parameter and the use of an active cooling technique (NIAC) might be used, even in combination, as effective tools for achieving proper macro and microstructure in WAAM of thin wall builds.

scholarly journals Effect of Filler Metal Type on Microstructure and Mechanical Properties of Fabricated NiAl Bronze Alloy Using Wire Arc Additive Manufacturing System

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 513
Author(s):  
Jae Won Kim ◽  
Jae-Deuk Kim ◽  
Jooyoung Cheon ◽  
Changwook Ji
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Filler Metal ◽  
Gas Metal Arc Welding ◽  
Metal Wire ◽  
Cold Metal Transfer ◽  
Metal Type ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

This study observed the effect of filler metal type on mechanical properties of NAB (NiAl-bronze) material fabricated using wire arc additive manufacturing (WAAM) technology. The selection of filler metal type is must consider the field condition, mechanical properties required by customers, and economics. This study analyzed the bead shape for representative two kind of filler metal types use to maintenance and fabricated a two-dimensional bulk NAB material. The cold metal transfer (CMT) mode of gas metal arc welding (GMAW) was used. For a comparison of mechanical properties, the study obtained three specimens per welding direction from the fabricated bulk NAB material. In the tensile test, the NAB material deposited using filler metal wire A showed higher tensile strength and lower elongation (approx. +71 MPa yield strength, +107.1 MPa ultimate tensile strength, −12.4% elongation) than that deposited with filler metal wire B. The reason is that, a mixture of tangled fine α platelets and dense lamellar eutectoid α + κIII structure with β´ phases was observed in the wall made with filler metal wire A. On the other hand, the wall made with filler metal wire B was dominated by coarse α phases and lamellar eutectoid α + κIII structure in between.

scholarly journals Wire and Arc Additive Manufacturing of High-Strength Al–Zn–Mg Aluminum Alloy

2021 ◽  
Vol 8 ◽  
Author(s):  
Xuewei Fang ◽  
Guopeng Chen ◽  
Jiannan Yang ◽  
Yang Xie ◽  
Ke Huang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Aluminum Alloys ◽  
Electron Backscatter Diffraction ◽  
Vertical Direction ◽  
High Strength ◽  
Thin Wall ◽  
Cold Metal Transfer ◽  
X Ray ◽  
Manufacturing Techniques ◽  
Cold Metal

High-strength 7xxx series aluminum alloys are of great importance for the aerospace industries. However, this type of aluminum alloys has poor processability for most additive manufacturing techniques. In this paper, a newly designed Al–Zn–Mg alloy was used as a feeding wire to fabricate thin wall-shaped samples using the wire and arc additive manufacturing (WAAM) technique. These samples were fabricated based on the cold metal transfer (CMT) process with four different types of arc modes, that is, CMT, CMT-incorporated pulse (CMT + P), CMT-incorporated polarity (CMT + A), CMT-incorporated pulse and polarity (CMT + PA). The optical microscopy, x-ray computed tomography, and scanning electron microscopy equipped with energy-dispersive x-ray spectroscopy (EDS) and electron backscatter diffraction (EBSD) were employed to characterize the microstructure and phase constitution. The results clearly reveal that the porosity varies with the arc modes, and the densest sample with porosity of 0.97% was obtained using the CMT + P mode. The mechanical properties of the fabricated samples are also dependent on the arc modes. The tensile strength and yield strength of the sample manufactured by the CMT + PA arc mode are the highest. In terms of anisotropy, the strength differences in horizontal and vertical direction of the samples made by CMT + PA, CMT + A, and CMT modes are all large, which is mainly ascribed to the pores distributed at the interlayer region.

scholarly journals Thermo-mechanical simulation of overlaid layers made with wire + arc additive manufacturing and GMAW-cold metal transfer

2020 ◽  
Vol 64 (8) ◽  
pp. 1427-1435 ◽  
Author(s):  
C. Cambon ◽  
S. Rouquette ◽  
I. Bendaoud ◽  
C. Bordreuil ◽  
R. Wimpory ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metal Transfer ◽  
Cold Metal Transfer ◽  
Mechanical Simulation ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

Effect of heat input on mechanical and microstructural properties of Inconel 625 depositions processed in wire arc additive manufacturing

2021 ◽  
pp. 095440892110047
Author(s):  
DT Sarathchandra ◽  
MJ Davidson
Keyword(s):  
Heat Input ◽  
Elevated Temperatures ◽  
Microstructural Characterization ◽  
Deposition Process ◽  
Columnar Structure ◽  
Inconel 625 ◽  
Cold Metal Transfer ◽  
Electron Microscopes ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

Inconel 625 alloy resists corrosion, fatigue and wear at elevated temperatures and hence they are used in aerospace, chemical, petrochemical, marine, and other high-temperature applications. In the present study, single beads of Inconel 625 were deposited using the cold metal transfer (CMT) based wire arc deposition process. Seven heat input conditions were used to study the microstructure and mechanical characteristics. Microstructural characterization was done with optical and scanning electron microscopes while microhardness was measured using the Vickers microhardness testing method. It has been observed that the microstructure of the deposited beads consists of a columnar structure with primary dendrites. Also, intermetallic elements like Niobium (Nb), Molybdenum (Mo), and Laves were formed. It was also observed that the percentage of Nb and Mo increases with heat input. The microhardness increases with an increase in heat input and the maximum hardness was found to be 234.7 HV.

Effect of depositing torch angle on the first layer of wire arc additive manufacture using cold metal transfer (CMT)

2019 ◽  
Vol 46 (2) ◽  
pp. 259-266 ◽  
Author(s):  
Chuanchu Su ◽  
Xizhang Chen
Keyword(s):  
Weld Pool ◽  
High Speed ◽  
Additive Manufacture ◽  
High Speed Camera ◽  
Porosity Formation ◽  
Cold Metal Transfer ◽  
Content Type ◽  
Deposition Direction ◽  
Cold Metal ◽  
Torch Angle

Purpose This paper aims to mainly report the impact of torch angle on the dynamic behavior of the weld pool which is recorded and monitored in real time with the aid of a high-speed camera system. The influence of depositing torch angle on the fluctuation behavior of weld pool and the quality of weld formation are compared and analyzed. Design/methodology/approach The FANUC controlled robotic manufacturing system comprised a Fronius cold metal transfer (CMT) Advanced 4000R power source, FANUC robot, water cooling system, wire feeding system and a gas shielding system. An infrared laser was used to illuminate the weld pool for high-speed imaging at 1,000 frames per second with CR600X2 high-speed camera. The high-speed camera was set up a 35 ° angle with the deposition direction to investigate the weld pool flow patterns derived from high-speed video and the effect of torch angles on the first layer of wire additive manufacture-CMT. Findings The experimental results demonstrated that different torch angles significantly influence on the deposited morphology, porosity formation rate and weld pool flow. Originality/value With regard to the first layer of wire arc additive manufacture of aluminum alloys, the change of torch angle is critical. It is clear that different torch angles significantly influence on the weld morphology, porosity formation and weld pool flow. Furthermore, under different torch angles, the deposited beads will produce different defects. To get well deposited beads, 0-10° torch could be made away from the vertical position of the deposition direction, in which the formation of deposited beads were well and less porosity and other defects.

scholarly journals Wire arc additive manufacturing of mild steel

2018 ◽  
Vol 65 (4) ◽  
pp. 179-186 ◽  
Author(s):  
Damjan Klobčar ◽  
Maja Lindič ◽  
Matija Bušić
Keyword(s):  
Additive Manufacturing ◽  
Dimensional Accuracy ◽  
Welding Parameters ◽  
Welding Robot ◽  
Plasma Welding ◽  
Cold Metal Transfer ◽  
Thin Walls ◽  
Manufacturing Technologies ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing

AbstractThis paper presents an overview of additive manufacturing technologies for production of metal parts. A special attention is set to wire arc additive manufacturing (WAAM) technologies, which include MIG/MAG welding, TIG welding and plasma welding. Their advantages compared to laser or electron beam technologies are lower investment and operational costs. However, these processes have lower dimensional accuracy of produced structures. Owing to special features and higher productivity, the WAAM technologies are more suitable for production of bigger parts. WAAM technology has been used together with welding robot and a cold metal transfer (CMT) power source. Thin walls have been produced using G3Si1 welding wire. The microstructure and hardness of produced structures were analysed and measured. A research was done to determine the optimal welding parameters for production of thin walls with smooth surface. A SprutCAM software was used to make a code for 3D printing of sample part.

scholarly journals Process response of Inconel 718 to wire + arc additive manufacturing with cold metal transfer

2020 ◽  
Vol 195 ◽  
pp. 109031
Author(s):  
Renan Medeiros Kindermann ◽  
M.J. Roy ◽  
R. Morana ◽  
Philip B. Prangnell
Keyword(s):  
Additive Manufacturing ◽  
Inconel 718 ◽  
Metal Transfer ◽  
Cold Metal Transfer ◽  
Cold Metal ◽  
Wire Arc Additive Manufacturing
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