Top

The International Journal of Advanced Manufacturing Technology

Published in:

02-07-2021 | Technical Note

Investigation of material characteristics of intersections built by wire and arc additive manufacturing using locally varying deposition parameters

Authors: Manuela Gudeljevic, Thomas Klein

Published in: The International Journal of Advanced Manufacturing Technology | Issue 5-6/2021

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

search-config

AI-assisted search

Off

Abstract

The application of wire and arc additive manufacturing to more complex structures can be accomplished if intersections can be generated without local variations in geometry, properties and microstructure. Here, the local modification of the deposition characteristic in the vicinity of the intersection is proposed. Consequently, higher building heights are feasible and further expansion of the technology’s field of application is enabled. Fabrication options for such structures are investigated using Al2319 alloy samples manufactured with a conventional and a modified welding characteristic. Furthermore, analysis of the intersections produced with the modified characteristic curve is carried out. The results show that the structure can be built without a limitation in height and unchanged characteristics regarding porosity, microstructure and hardness values. Therefore, the presented deposition strategy can be used for a wide range of future structures, as it increases the design freedom.

previous article Real-time chatter detection via iterative Vold-Kalman filter and energy entropy

next article Electrochemical machining of array flow channels using cathode tool with comb-shaped insulator

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

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

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/10.1080/02670836.2018.1455012CrossRef

Fang X, Zhang L, Li H, Li C, Huang K, Lu B (2018) Microstructure evolution and mechanical behavior of 2219 aluminum alloys additively fabricated by the cold metal transfer process. Materials (Basel) 11:50812. https://doi.org/10.3390/ma11050812CrossRef

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.2018.07.030CrossRef

Martina F, Williams SW (2015) Wire+arc additive manufacturing vs. traditional machining from solid: a cost comparison., Report, Available from: https://waammat.com/documents/waam-vs-machining-from-solid-a-cost-comparison, accessed date: 03/04/2021.

Hönnige JR, Colegrove PA, Ganguly S, Eimer E, Kabra S, Williams S (2018) Control of residual stress and distortion in aluminium wire + arc additive manufacture with rolling. Addit Manuf 22:775–783. https://doi.org/10.1016/j.addma.2018.06.015CrossRef

Wu B, Ding D, Pan Z et al (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.2017.07.037CrossRef

Rosli NA, Alkahari MR, Abdollah MF et al (2021) Review on effect of heat input for wire arc additive manufacturing process. J Mater Res Technol 11:2127–2145. https://doi.org/10.1016/j.jmrt.2021.02.002CrossRef

Li C, Gu H, Wang W, Wang S, Ren L, Wang Z, Ming Z, Zhai Y (2020) Effect of heat input on formability, microstructure, and properties of Al-7Si-0.6Mg alloys deposited by CMT-WAAM process. Appl Sci 10:10070. https://doi.org/10.3390/app10010070CrossRef

10.

Klein T, Schnall M (2020) Control of macro-/microstructure and mechanical properties of a wire-arc additive manufactured aluminum alloy. Int J Adv Manuf Technol 108:235–244. https://doi.org/10.1007/s00170-020-05396-6CrossRef

11.

Sames WJ, List FA, Pannala S, Dehoff RR, Babu SS (2016) The metallurgy and processing science of metal additive manufacturing. Int Mater Rev 61:315–360. https://doi.org/10.1080/09506608.2015.1116649CrossRef

12.

Shipley H, McDonnell D, Culleton M, Coull R, Lupoi R, O'Donnell G, Trimble D (2018) Optimisation of process parameters to address fundamental challenges during selective laser melting of Ti-6Al-4V: a review. Int J Mach Tools Manuf 128:1–20. https://doi.org/10.1016/j.ijmachtools.2018.01.003CrossRef

13.

Shamsaei N, Yadollahi A, Bian L, Thompson SM (2015) An overview of direct laser deposition for additive manufacturing; Part II: mechanical behavior, process parameter optimization and control. Addit Manuf 8:12–35. https://doi.org/10.1016/j.addma.2015.07.002CrossRef

14.

Jiang J, Ma Y (2020) Path planning strategies to optimize accuracy, quality, build time and material use in additive manufacturing: a review. Micromachines 11:633. https://doi.org/10.3390/MI11070633CrossRef

15.

Lockett H, Ding J, Williams S, Martina F (2017) Design for wire + arc additive manufacture: design rules and build orientation selection. J Eng Des 28:568–598. https://doi.org/10.1080/09544828.2017.1365826CrossRef

16.

Mehnen J, Ding J, Lockett H, Kazanas P (2014) Design study for wire and arc additive manufacture. Int J Prod Dev 19:2–20. https://doi.org/10.1504/IJPD.2014.060028CrossRef

17.

Cunningham CR, Flynn JM, Shokrani A, Dhokia V, Newman ST (2018) Invited review article: strategies and processes for high quality wire arc additive manufacturing. Addit Manuf 22:672–686. https://doi.org/10.1016/j.addma.2018.06.020CrossRef

18.

Venturini G, Montevecchi F, Scippa A, Campatelli G (2016) Optimization of WAAM deposition patterns for T-crossing features. Proc CIRP 55:95–100. https://doi.org/10.1016/j.procir.2016.08.043CrossRef

19.

Michel F, Lockett H, Ding J, Martina F, Marinelli G, Williams S (2019) A modular path planning solution for wire + arc additive manufacturing. Robot Comput Integr Manuf 60:1–11. https://doi.org/10.1016/j.rcim.2019.05.009CrossRef

20.

Rodrigues TA, Duarte V, Miranda RM, Santos TG, Oliveira JP (2019) Current status and perspectives on wire and arc additive manufacturing (WAAM). Materials (Basel) 12. https://doi.org/10.3390/ma12071121

21.

Gu J, Bai J, Ding J, Williams S, Wang L, Liu K (2018) Design and cracking susceptibility of additively manufactured Al-Cu-Mg alloys with tandem wires and pulsed arc. J Mater Process Technol 262:210–220. https://doi.org/10.1016/j.jmatprotec.2018.06.030CrossRef

22.

Klein T, Schnall M, Gomes B, Warczok P, Fleischhacker D, Morais PJ (2021) Wire-arc additive manufacturing of a novel high-performance Al-Zn-Mg-Cu alloy: processing, characterization and feasibility demonstration. Addit Manuf 37:101663. https://doi.org/10.1016/j.addma.2020.101663CrossRef

23.

Seyda V (2018) Werkstoff- und Prozessverhalten von Metallpulvern in der laseradditiven Fertigung. Springer Vieweg, Berlin. https://doi.org/10.1007/978-3-662-58233-6CrossRef

24.

Gu J, Gao M, Yang S, Bai J, Ding J, Fang X (2019) Pore formation and evolution in wire + arc additively manufactured 2319 Al alloy. Addit Manuf 30:100900. https://doi.org/10.1016/j.addma.2019.100900CrossRef

25.

Xue Y, Pascu A, Horstemeyer MF et al (2010) Microporosity effects on cyclic plasticity and fatigue of LENS^TM-processed steel. Acta Mater 58:4029–4038. https://doi.org/10.1016/j.addma.2019.100900CrossRef

26.

Cong B, Ding J, Williams S (2015) 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-xCrossRef

27.

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.2015.11.006CrossRef

28.

Gu J, Cong B, Ding J, et al Wire+arc additive manufacturing of aluminium. Report, Available from: http://utw10945.utweb.utexas.edu/sites/default/files/2014-038-Gu.pdf, Accessed date: 03/04/2021.

29.

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.2018.04.014CrossRef

30.

Markov OE, Gerasimenko OV, Shapoval AA, Abdulov OR, Zhytnikov RU (2019) Computerized simulation of shortened ingots with a controlled crystallization for manufacturing of high-quality forgings. Int J Adv Manuf Technol 103:3057–3065. https://doi.org/10.1007/s00170-019-03749-4CrossRef

31.

Sanaei N, Fatemi A (2020) Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review. Prog Mater Sci 117:100724. https://doi.org/10.1016/j.pmatsci.2020.100724CrossRef

32.

Köhler M, Fiebig S, Hensel J, Dilger K (2019) Wire and arc additive manufacturing of aluminum components. Metals (Basel) 9:1–9. https://doi.org/10.3390/met9050608CrossRef

Title: Investigation of material characteristics of intersections built by wire and arc additive manufacturing using locally varying deposition parameters
Authors: Manuela Gudeljevic
Thomas Klein
Publication date: 02-07-2021
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 5-6/2021
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-021-07548-8

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 5-6/2021

Influence of isothermal aging in LDX 2101 duplex stainless steel on the microstructure and local properties

Voxel-based modeling of transient material removal in machining

A novel polishing technology for leading and trailing edges of aero-engine blade

Microstructural and mechanical property investigation of machined surface layer in high-speed milling of Ti-6Al-4V alloy

A path planning method of lattice structural components for additive manufacturing

Effect of magnetic field on tension–tension side of forming limit diagram in sheet metal forming using a magnetorheological fluid

Premium Partners