Top

The International Journal of Advanced Manufacturing Technology

Published in:

15-02-2020 | ORIGINAL ARTICLE

Effect of pulsed metal inert gas (pulsed-MIG) and cold metal transfer (CMT) techniques on hydrogen dissolution in wire arc additive manufacturing (WAAM) of aluminium

Authors: Karan S. Derekar, Adrian Addison, Sameehan S. Joshi, Xiang Zhang, Jonathan Lawrence, Lei Xu, Geoff Melton, David Griffiths

Published in: The International Journal of Advanced Manufacturing Technology | Issue 1-2/2020

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Aluminium is one of the most experimented metals in the WAAM field owing to a wide range of applications in the automotive sector. Due to concerns over reduction of strength, elimination of porosity from wire arc additive manufactured aluminium is one of the major challenges. In line with this, the current investigation presents findings on hydrogen dissolution in solid aluminium and hydrogen consumed to form porosity along with its distribution as a function of heat inputs and interlayer temperatures in a WAAM 5183 aluminium alloy. Two varieties of WAAM, pulsed metal inert gas (MIG) and cold metal transfer (CMT), were explored. Samples made with pulsed metal inert gas (pulsed-MIG) process picked up more hydrogen compared to samples produced by cold metal transfer technique. Correspondingly, pulsed-MIG samples showed increased number of pores and volume fraction of porosity than samples manufactured using the cold metal transfer (CMT) technique for different heat input and interlayer temperature conditions. However, CMT samples exhibited higher amount of dissolved hydrogen in solid solution compared to pulsed-MIG process. In addition, heat input, interlayer temperature, and interlayer dwell time also played a key role in pore formation and distribution in WAAM-produced aluminium 5183 alloy.

previous article Characterization and optimization of the hydroforming process of AISI 316L steel hydraulic tubes

next article Die-sinking EDM of Al6061-T6: interactions between process parameters, process performance, and surface characteristics

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Available only for authorised users

Derekar KS (2018) A review of wire arc additive manufacturing and advances in wire arc additive manufacturing of aluminium. Mater Sci Technol (United Kingdom) 34:895–916. https://doi.org/10.1080/02670836.2018.1455012 CrossRef

Martina F, Mehnen J, Williams SW, Colegrove P, Wang F (2012) Investigation of the benefits of plasma deposition for the additive layer manufacture of Ti-6Al-4V. J Mater Process Technol 212:1377–1386. https://doi.org/10.1016/j.jmatprotec.2012.02.002 CrossRef

Williams SW, Martina F, Addison AC, Ding J, Pardal G, Colegrove P (2016) Wire + arc additive manufacturing. Mater Sci Technol 32:641–647. https://doi.org/10.1179/1743284715Y.0000000073 CrossRef

Yang D, He C, Zhang G (2016) Forming characteristics of thin-wall steel parts by double electrode GMAW based additive manufacturing. J Mater Process Technol 227:153–160. https://doi.org/10.1016/j.jmatprotec.2015.08.021 CrossRef

Zhang C, Li Y, Gao M, Zeng X (2018) Wire arc additive manufacturing of Al-6Mg alloy using variable polarity cold metal transfer arc as power source. Mater Sci Eng A 711:415–423. https://doi.org/10.1016/j.msea.2017.11.084 CrossRef

Fang X, Zhang L, Chen G, Dang X, Huang K, Wang L, Lu B (2018) Correlations between microstructure characteristics and mechanical properties in 5183 aluminium alloy fabricated by wire-arc additive manufacturing with different arc modes. Materials (Basel) 11. https://doi.org/10.3390/ma11112075 CrossRef

Gu J, Wang X, Bai J, Ding J, Williams S, Zhai Y, Liu K (2018) Deformation microstructures and strengthening mechanisms for the wire+arc additively manufactured Al-Mg4.5Mn alloy with inter-layer rolling. Mater Sci Eng A 712:292–301. https://doi.org/10.1016/j.msea.2017.11.113 CrossRef

Gu J, Ding J, Williams SW, Gu H, Bai J, Zhai Y, Ma P (2016) The strengthening effect of inter-layer cold working and post-deposition heat treatment on the additively manufactured Al-6.3Cu alloy. Mater Sci Eng A 651:18–26. https://doi.org/10.1016/j.msea.2015.10.101 CrossRef

Gu J, Cong B, Ding J, Williams SW, Zhai Y (2014) Wire+arc additive manufacturing of Aluminium, in: Proc 25th Annu Int solid free Fabr Symp, Austin, Texas, pp 4–6

10.

Qi Z, Cong B, Qi B, Sun H, Zhao G, Ding J (2018) Microstructure and mechanical properties of double-wire + arc additively manufactured Al-Cu-Mg alloys. J Mater Process Technol 255:347–353. https://doi.org/10.1016/j.jmatprotec.2017.12.019 CrossRef

11.

Gu J, Ding J, Williams SW, Gu H, Ma P, Zhai Y (2016) The effect of inter-layer cold working and post-deposition heat treatment on porosity in additively manufactured aluminum alloys. J Mater Process Technol 230:26–34. https://doi.org/10.1016/j.jmatprotec.2015.11.006 CrossRef

12.

Cong B, Ding J, Williams S (2014) Effect of arc mode in cold metal transfer process on porosity of additively manufactured Al-6.3%Cu alloy. Int J Adv Manuf Technol 76:1593–1606. https://doi.org/10.1007/s00170-014-6346-x CrossRef

13.

Horgar A, Fostervoll H, Nyhus B, Ren X, Eriksson M, Akselsen OM (2018) Additive manufacturing using WAAM with AA5183 wire. J Mater Process Technol 259:68–74. https://doi.org/10.1016/j.jmatprotec.2018.04.014 CrossRef

14.

Yousefian P, Tiryakioğlu M (2018) Pore formation during solidification of aluminum: reconciliation of experimental observations, modeling assumptions, and classical nucleation theory. Metall Mater Trans A Phys Metall Mater Sci 49:563–575. https://doi.org/10.1007/s11661-017-4438-6 CrossRef

15.

Mathers G (2002) The welding of aluminium and its alloys. Woodhead publishing limited, Cambridge England. https://doi.org/10.1533/9781855737631.1 CrossRef

16.

Devletian J, Wood W (1983) Factors affecting porosity in aluminum welds - a review. Weld Res Counc 290:1–18

17.

Geng H, Li J, Xiong J, Lin X (2017) Optimisation of interpass temperature and heat input for wire and arc additive manufacturing 5A06 aluminium alloy. Sci Technol Weld Join 22:472–483. https://doi.org/10.1080/13621718.2016.1259031 CrossRef

18.

Ryan EM, Sabin TJ, Watts JF, Whiting MJ (2018) The influence of build parameters and wire batch on porosity of wire and arc additive manufactured aluminium alloy 2319. J Mater Process Technol 262:577–584. https://doi.org/10.1016/j.jmatprotec.2018.07.030 CrossRef

19.

Gu JL, Ding JL, Cong BQ, Bai J, Gu HM, Williams SW, Zhai YC (2014) The influence of wire properties on the quality and performance of wire+arc additive manufactured aluminium parts. Adv Mater Res 1081:210–214. https://doi.org/10.4028/www.scientific.net/AMR.1081.210 CrossRef

20.

Cong B, Qi Z, Qi B, Sun H, Zhao G, Ding J (2017) A comparative study of additively manufactured thin wall and block structure with Al-6.3%Cu alloy using cold metal transfer process. Appl Sci 7:275. https://doi.org/10.3390/app7030275 CrossRef

21.

Kou S (2003) Metallurgy Second Edition Welding Metallurgy. https://doi.org/10.1016/j.theochem.2007.07.017 CrossRef

22.

Cong B, Ouyang R, Qi B, Ding J (2016) Influence of cold metal transfer process and its heat input on weld bead geometry and porosity of aluminum-copper alloy welds. Rare Metal Mater Eng 45:606–611. https://doi.org/10.1016/S1875-5372(16)30080-7 CrossRef

23.

Gao YX, Yi JZ, Lee PD, Lindley TC (2004) The effect of porosity on the fatigue life of cast aluminium-silicon alloys. Fatigue Fract Eng Mater Struct 27:559–570. https://doi.org/10.1111/j.1460-2695.2004.00780.x CrossRef

24.

Wu B, Ding D, Pan Z, Cuiuri D, Li H, Han J, Fei Z (2017) Effects of heat accumulation on the arc characteristics and metal transfer behavior in wire arc additive manufacturing of Ti6Al4V. J Mater Process Technol 250:304–312. https://doi.org/10.1016/j.jmatprotec.2017.07.037 CrossRef

25.

Xiong J, Lei Y, Li R (2017) Finite element analysis and experimental validation of thermal behavior for thin-walled parts in GMAW-based additive manufacturing with various substrate preheating temperatures. Appl Therm Eng 126:43–52. https://doi.org/10.1016/j.applthermaleng.2017.07.168 CrossRef

26.

Xiong J, Li R, Lei Y, Chen H (2018) Heat propagation of circular thin-walled parts fabricated in additive manufacturing using gas metal arc welding. J Mater Process Technol 251:12–19. https://doi.org/10.1016/j.jmatprotec.2017.08.007 CrossRef

27.

Grigorenko G (1970) Formation of pores in welds. Avtom Svarka 10:13–17

28.

Hasegawa M (2014) Ellingham diagram. Elsevier Ltd. https://doi.org/10.1016/B978-0-08-096986-2.00032-1 CrossRef

29.

Hashimoto E, Kino T (1983) Hydrogen diffusion in aluminium at high temperatures. J Phys F Met Phys 13:1157–1165. https://doi.org/10.1088/0305-4608/13/6/013 CrossRef

30.

Wang P, Hu S, Shen J, Liang Y (2017) Characterization the contribution and limitation of the characteristic processing parameters in cold metal transfer deposition of an Al alloy. J Mater Process Technol 245:122–133. https://doi.org/10.1016/j.jmatprotec.2017.02.019 CrossRef

31.

Chalmers B (1970) Principles of solidification. In: Appl Solid State Phys. Springer, Boston, pp 161–170. https://doi.org/10.1007/978-1-4684-1854-5_5 CrossRef

32.

Llnderoth S (1988) Hydrogen diffusivity in aluminium. Philos Mag Lett 57:229–234. https://doi.org/10.1080/09500838808214712 CrossRef

33.

Derekar K, Lawrence J, Melton G, Addison A, Zhang X, Xu L (2019) Influence of interpass temperature on wire arc additive manufacturing (WAAM) of aluminium alloy components. In: MATEC Web Conf, p 05001. https://doi.org/10.1051/matecconf/201926905001 CrossRef

Title: Effect of pulsed metal inert gas (pulsed-MIG) and cold metal transfer (CMT) techniques on hydrogen dissolution in wire arc additive manufacturing (WAAM) of aluminium
Authors: Karan S. Derekar
Adrian Addison
Sameehan S. Joshi
Xiang Zhang
Jonathan Lawrence
Lei Xu
Geoff Melton
David Griffiths
Publication date: 15-02-2020
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 1-2/2020
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-020-04946-2

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 1-2/2020

Ultrasonic spot welding of aluminum to copper: a review

Peg-on-hole: mathematical investigation of motion of a peg and of forces of its interaction with a vertically fixed hole during their alignment with a three-point contact

Effects of cobalt and solidification cooling rate on intermetallic phases and tensile properties of a -Cu, -Zn, -Fe containing Al-Si alloy

A scan-wise adaptive remeshing framework for thermal simulation of the selective laser melting process

Effect of ultrasonic vibration on thermal and material flow behavior, microstructure and mechanical properties of friction stir welded Al/Cu joints

Surface based variable thickness slicing modeling for laser metal deposition

Premium Partners