scholarly journals Additive Manufacturing of Ti6Al4V with Wire Laser Metal Deposition Process

2021 ◽  
Vol 1016 ◽  
pp. 24-29
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Deposition Process ◽  
Travel Speed ◽  
Beam Power ◽  
Feed Speed ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Growth Prospects ◽  
Wire Feed

Additive manufacturing (AM) using wire as an input material is currently in full swing, with very strong growth prospects thanks to the possibility of creating large parts, with high deposition rates, but also a low investment cost compared to the powder bed fusion machines. A versatile 3D printing device using a Direct Energy Deposition Wire-Laser (DED-W Laser) with Precitec Coaxprinter station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters. The geometrical and metallurgical of produced parts are analyzed. In the literature, several authors agree to define wire feed speed, travel speed, and laser beam power as first-order process parameters governing laser-wire deposition. This study shows the relative importance of these parameters taking separately as well as the importance of their sequencing at the start of the process. Titanium deposit are obtained with powers never explored in bibliography (up to 5 kW), and wire feed speed up to 5 m.min-1 with a complete process repeatability.

scholarly journals Study of the Impact of the Synergic Line and the Strategy of Conception on Ti-6Al-4V Wire Arc Additive Manufacturing Process (WAAM-CMT)

2021 ◽  
Vol 1016 ◽  
pp. 250-255
Author(s):  
Achraf Ayed ◽  
Guénolé Bras ◽  
Henri Bernard ◽  
Pierre Michaud ◽  
Yannick Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Travel Speed ◽  
Feed Speed ◽  
Thin Walls ◽  
Direct Energy ◽  
Wire Feed Speed ◽  
Manufacturing Technologies ◽  
The Impact ◽  
Wire Arc Additive Manufacturing

In additive manufacturing, technologies based on the fusion of a metallic wire using an electric arc represent an interesting alternative to current manufacturing processes, particularly for large metal parts, thanks to higher deposition rates and lower process costs than powder or wire-laser technologies. A versatile 3D printing device using a DED-W Arc (Direct Energy Deposition by wire-arc) station to melt a metallic filler wire is developed to build titanium parts by optimizing the process parameters and control the geometrical, metallurgical and the mechanical properties of produced parts. In this study, the impact of two different CMT synergic lines on the energetic and geometric behavior of Ti-6Al-4V single deposits is highlighted. These are related to first order parameters: wire feed speed (WFS) and travel speed (TS). The results show difference on energy, geometric of deposits and different deposition regime between these two law with identical process parameters. The second part of this study focuses on the transition from single deposits to walls and blocks. By first choosing the best set of process parameters to make the construction of thin walls (composed of stacked layers), and then the research the optimal horizontal step of deposition (overlapping) for thicker constructions, results obtained made it possible to validate transition from single deposits (1D) to thick walls (3D) without any weld pool collapse or lack of fusion.

Process Development for a Robotized Laser Wire Additive Manufacturing

2017 ◽  
Author(s):  
Meysam Akbari ◽  
Yaoyu Ding ◽  
Radovan Kovacevic
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Process Development ◽  
Laser Scanner ◽  
Travel Speed ◽  
Main Process ◽  
Feed Speed ◽  
Wire Feed Speed ◽  
Deposition Processes ◽  
Complicated Geometries

Additive manufacturing has attracted the attention of industries such as aerospace and automotive as well as the medical technology sectors in recent years. Among all metal-based additive techniques, laser metal wire deposition offers some advantages like shorter processing time, more efficient material usage, and a larger buildup envelop. It has been found that robotized laser/wire additive manufacturing (RLWAM) is a demanding process. A plethora of process parameters must be controlled compared to other laser-based metal deposition processes. The influence of main process parameters such as laser power, stepover increment, wire feed speed, travel speed and z-increment was investigated in this study to find the optimal values. Droplet formation, wire dripping, irregular deposition in the first layer, and deviation of the wire tip were also found to be the main obstacles throughout the process and practical solutions were proposed to deal with these issues. In this study, an 8-axis robot (6-axis arm robot with a 2-axis positioner) and a 4 kW fiber laser along with a wire feeder were integrated to print the different geometrical shapes in 3D. In order to verify the geometrical accuracy of the as-built part, the buildup was scanned using a portable 3D laser scanner. The 3D representation, the Standard Tessellation Language (STL) format obtained from the buildup, was compared with the original CAD model. The results show that RLWAM can be successfully applied in printing even complicated geometries.

scholarly journals Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts

2020 ◽  
Vol 321 ◽  
pp. 03002
Author(s):  
A. Ayed ◽  
G. Bras ◽  
H. Bernard ◽  
P. Michaud ◽  
Y. Balcaen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Feed Speed ◽  
Laser Additive Manufacturing ◽  
Powder Bed ◽  
Wire Feed Speed ◽  
Manufacturing Techniques ◽  
Parameter Ranges ◽  
Wire Arc Additive Manufacturing ◽  
Wire Feed

Arc-wire or laser-wire additive manufacturing seems promising because it allows large parts to be produced with significant deposition rates (ten times higher than powder bed additive manufacturing), for a lower investment cost. These additive manufacturing techniques are also very interesting for the construction or the repair of parts. A versatile 3D printing device using a Wire Arc Additive Manufacturing (WAAM) station or laser device Wire Laser Additive Manufacturing (WLAM) for melting a filler wire is developed to repair and build large titanium parts. The final objectives of the study are to optimize the process parameters to control the dimensional stability, the metallurgical and mechanical properties of the produced parts. In this paper, an experimental study is carried out to determine the first order process parameter ranges (synergic law, laser power, wire feed speed, travel speed) appropriate for these two techniques, for repair or construction parts on Ti-6 Al-4V.

scholarly journals Balancing WAAM Production Costs and Wall Surface Quality through Parameter Selection: A Case Study of an Al-Mg5 Alloy Multilayer-Non-Oscillated Single Pass Wall

2019 ◽  
Vol 3 (2) ◽  
pp. 32 ◽  
Author(s):  
Yuri Yehorov ◽  
Leandro João da Silva ◽  
Américo Scotti
Keyword(s):  
Deposition Time ◽  
Travel Speed ◽  
Production Costs ◽  
Constant Current ◽  
Feed Speed ◽  
Surface Waviness ◽  
Single Pass ◽  
Target Wall ◽  
Wire Feed Speed ◽  
Wire Feed

The purpose of the study was to propose a strategy to assess the potential reduction of the production cost during wire+arc additive manufacturing (WAAM) based on the combination of wire feed speed (related to deposition rate) and travel speed (related to deposition time). A series of experiments, using a multilayer-non-oscillated single pass wall made of an Al-Mg alloy, was conducted. The quality of the wall was assessed through the lateral surface waviness and top layer undulation. The concepts of Surface Waviness and Buy-to-Apply indices were introduced. Initially, the range of travel speed (TS) that provided layers with acceptable quality was determined for a given wire feed speed (WFS), corresponding to a constant current. Then, the effect of the increase of production capacity of the process (though current raising, yet maintaining the ratio WFS/TS constant) on the wall quality for a given condition within the TS range was assessed. The results showed that the useful range of TS prevents too rough a waving surface below the lower limit and top surface undulation over the higher limit. However, inside the range, there is little quality variation for the case under study. Finally, simulations of deposition time were developed to demonstrate the weight of the TS on the final deposition time and wall quality as a function of a target wall width. This respective weight showed the existence of a complex and unpredictable, yet determined, power of a combination of TS, target wall geometry, and dead time between subsequent layers. It was verified to be possible to find optimized TS as a function of different target geometries.

scholarly journals A Parametric Study of Additive Manufacturing Process: TA6V Laser Wire Metal Deposition

2021 ◽  
pp. 15-20
Author(s):  
Valentine Cazaubon ◽  
Audrey Abi Akle ◽  
Xavier Fischer
Keyword(s):  
Additive Manufacturing ◽  
Laser Power ◽  
Pearson Correlation ◽  
Metal Deposition ◽  
Feed Speed ◽  
New Process ◽  
Wire Feed Speed ◽  
Subtractive Manufacturing ◽  
Working Principle ◽  
Wire Feed

AbstractAdditive Manufacturing has proven to be an economically and industrially attractive process in building or repairing parts. However, the major issue of this new process is to guarantee a mechanical behavior identical to the subtractive manufacturing methodologies. The work, presented in this paper, is centered on the Laser Wire Metal Deposition (LMD-w) method with the metallic alloy TA6V. Its working principle is to fuse a coaxial wire on a substrate with a laser as a heat source. To better understand the interaction between the input parameters (Laser Power, Wire Feed Speed and Tool Speed) and the clad geometry output variables (Height, Width and Contact Angle) and the substrate displacement, we have realized an experimentation. We printed 9 clads according Taguchi’s experimental design. Pearson correlation coefficient and Fisher test performed on the experimental measures showed as main result: Tool Speed is the parameter with the most significant influence on the output variables.

Formation and improvement of surface waviness for additive manufacturing 5A06 aluminium alloy component with GTAW system

2018 ◽  
Vol 24 (2) ◽  
pp. 342-350 ◽  
Author(s):  
Haibin Geng ◽  
Jinglong Li ◽  
Jiangtao Xiong ◽  
Xin Lin ◽  
Dan Huang ◽  
...  
Keyword(s):  
Travel Speed ◽  
Feed Speed ◽  
Surface Waviness ◽  
Forming Process ◽  
Line Energy ◽  
Content Type ◽  
Wire Feed Speed ◽  
The Given ◽  
Wire Feed ◽  
Matching Relation

Purpose As known, the wire and arc additive manufacture technique can achieve stable process control, which is represented with periodic surface waviness, when using empirical methods or feedback control system. But it is usually a tedious work to further reduce it using trial and error method. The purpose of this paper is to unveil the formation mechanism of surface waviness and develop a method to diminish it. Design/methodology/approach Two forming mechanisms, wetting and spreading and remelting, are unveiled by cross-section observation. A discriminant is established to differentiate which mechanism is valid to dominate the forming process under the given process parameters. Findings Finally, a theoretical method is developed to optimize surface waviness, even forming a smooth surface by establishing a matching relation between heat input (line energy) and materials input (the ratio of wire feed speed to travel speed). Originality/value Formation mechanisms are revealed by observing cross-section morphology. A discriminant is established to differentiate which mechanism is valid to dominate the forming process under the given process parameters. A mathematical model is developed to optimize surface waviness, even forming a smooth surface through establishing a matching relation between heat input (line energy) and materials input (the ratio of wire feed speed to travel speed).

Application of MIG Welding Process of Mild Steel Wire in Additive Manufacturing

2021 ◽  
Vol 877 ◽  
pp. 73-79
Author(s):  
Pattarawadee Poolperm ◽  
Wasawat Nakkiew ◽  
Nirut Naksuk
Keyword(s):  
Additive Manufacturing ◽  
Steel Wire ◽  
Welding Process ◽  
Feed Speed ◽  
Mig Welding ◽  
Microhardness Testing ◽  
Wire Feed Speed ◽  
Forming Characteristics ◽  
Arc Current ◽  
Wire Feed

The purpose of this study is to investigate the forming characteristics of single-pass Metal Inert Gas (MIG) welding wire for multi-layer additive manufacturing parts. Influences of arc current, arc voltage, arc distances, welding speed, wire feed speed, temperatures and heat input on layer formation were analyzed. The deposition of material by MIG process is controlled by a robot (ABB) controller for constructing walls of rectangular box shape. The samples were measured with a microhardness testing and tensile testing onto the welded bead created by the additive manufacturing technique. It was found that the mechanical properties of microhardness values are between 151.70 to 155.80 HV and the tensile strength values are between 472.71 to 491.12 MPa according to transverse and longitudinal sections of the specimens.

scholarly journals Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4265
Author(s):  
Bobo Li ◽  
Bowen Wang ◽  
Greg Zhu ◽  
Lijuan Zhang ◽  
Bingheng Lu
Keyword(s):  
Additive Manufacturing ◽  
High Surface ◽  
Deposition Process ◽  
High Energy ◽  
Width Ratio ◽  
Thin Wall ◽  
Small Power ◽  
High Surface Quality ◽  
Wall Structures ◽  
Wire Feed

Aiming at handling the contradiction between power constraint of on-orbit manufacturing and the high energy input requirement of metal additive manufacturing (AM), this paper presents an AM process based on small-power metal fine wire feed, which produces thin-wall structures of height-to-width ratio up to 40 with core-forming power only about 50 W. In this process, thermal resistance was introduced to optimize the gradient parameters which greatly reduces the step effect of the typical AM process, succeeded in the surface roughness (Ra) less than 5 μm, comparable with that obtained by selective laser melting (SLM). After a 10 min electrolyte-plasma process, the roughness of the fabricated specimen was further reduced to 0.4 μm, without defects such as pores and cracks observed. The ultimate tensile strength of the specimens measured about 500 MPa, the relative density was 99.37, and the Vickers hardness was homogeneous. The results show that the proposed laser-Joule wire feed-direct metal deposition process (LJWF-DMD) is a very attractive solution for metal AM of high surface quality parts, particularly suitable for rapid prototyping for on-orbit AM in space.

Correlation between wire feed speed and external mechanical constraint for enhanced process stability in underwater wet flux-cored arc welding

2018 ◽  
Vol 233 (10) ◽  
pp. 2061-2073 ◽  
Author(s):  
Jianfeng Wang ◽  
Qingjie Sun ◽  
Jiangkun Ma ◽  
Peng Jin ◽  
Tianzhu Sun ◽  
...  
Keyword(s):  
Welding Process ◽  
Electrical Signal ◽  
Feed Speed ◽  
Process Stability ◽  
Underwater Wet Welding ◽  
Extinction Process ◽  
Flux Cored Arc Welding ◽  
Wire Feed Speed ◽  
Wire Feed ◽  
Mechanical Constraint

It is a great challenge to improve the process stability in conventional underwater wet welding due to the formation of unstable bubble. In this study, mechanical constraint method was employed to interfere the bubble generated by underwater wet welding, and the new method was named as mechanical constraint assisted underwater wet welding. The aim of the study was to quantify the combined effect of wire feed speed and condition of mechanical constraint on the process stability in mechanical constraint assisted underwater wet welding. Experimental results demonstrated that the introduction of mechanical constraint not only suppressed the bubble without floating but also stabilized the arc burning process. The degree of influence of mechanical constraint, which changed with wire feed speed, played an important role during the mechanical constraint assisted underwater wet welding process. For all wire feed speeds, the fluctuations of welding electrical signal were decreased through introduction of mechanical constraint. The difference in the proportion of arc extinction process between underwater wet welding and mechanical constraint assisted underwater wet welding became less with increasing wire feed speed. At wire feed speed lower than 7.5 m/min, the improvement of process stability was very significant by mechanical constraint. However, the further improvement produced limited effect when the wire feed speed was greater than 7.5 m/min. The observation results showed that a better weld appearance was afforded at a large wire feed speed, corresponding to a lower variation coefficient.

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