Additive manufacturing of metallic components – Process, structure and properties

A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement

Wire Arc Additive Manufacturing (WAAM) is attracting significant attention in industry and academia due to its ability to capture the benefits of additive manufacturing for production of large components of medium geometric complexity. Uniquely, WAAM combines the use of wire and electric arc as a fusion source to build components in a layer-by-layer approach, both of which can offer significant cost savings compared to powder and alternative fusion sources, such as laser and electron beam, respectively. Meanwhile, a high deposition rate, key for producing such components, is provided, whilst also allowing significant material savings compared to conventional manufacturing processes. However, high quality production in a wide range of materials is limited by the elevated levels of heat input which causes a number of materials processing challenges in WAAM. The materials processing challenges are fully identified in this paper to include the development of high residual stresses, undesirable microstructures, and solute segregation and phase transformations at solidification. The thermal profile during the build poses another challenge leading to heterogeneous and anisotropic material properties. This paper outlines how the materials processing challenges may be addressed in WAAM by implementation of quality improving ancillary processes. The primary WAAM process selections and ancillary processes are classified by the authors and a comprehensive review of their application conducted. Strategies by which the ancillary processes can enhance the quality of WAAM parts are presented. The efficacy and suitability of these strategies for versatile and cost effective WAAM production are discussed and a future vision of WAAM process developments provided.

https://purehost.bath.ac.uk/ws/files/183236429/StrategiesAndProcessesForHighQualityWireArcAdditiveManufacturing_Manuscript.pdf

Invited review article: Strategies and processes for high quality wire arc additive manufacturing

Additive manufacturing has revolutionized the manufacturing paradigm in recent years due to the possibility of creating complex shaped three-dimensional parts which can be difficult or impossible to obtain by conventional manufacturing processes. Among the different additive manufacturing techniques, wire and arc additive manufacturing (WAAM) is suitable to produce large metallic parts owing to the high deposition rates achieved, which are significantly larger than powder-bed techniques, for example. The interest in WAAM is steadily increasing, and consequently, significant research efforts are underway. This review paper aims to provide an overview of the most significant achievements in WAAM, highlighting process developments and variants to control the microstructure, mechanical properties, and defect generation in the as-built parts; the most relevant engineering materials used; the main deposition strategies adopted to minimize residual stresses and the effect of post-processing heat treatments to improve the mechanical properties of the parts. An important aspect that still hinders this technology is certification and nondestructive testing of the parts, and this is discussed. Finally, a general perspective of future advancements is presented.

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

The off-stoichiometric Ni2MnGa Heusler alloy is a magnetic shape-memory alloy capable of reversible magnetic-field-induced strains (MFIS). These are generated by twin boundaries moving under the influence of an internal stress produced by a magnetic field through the magnetocrystalline anisotropy. While MFIS are very large (up to 10%) for monocrystalline Ni-Mn-Ga, they are near zero (<0.01%) in fine-grained polycrystals due to incompatibilities during twinning of neighboring grains and the resulting internal geometrical constraints. By growing the grains and/or shrinking the sample, the grain size becomes comparable to one or more characteristic sample sizes (film thickness, wire or strut diameter, ribbon width, particle diameter, etc), and the grains become surrounded by free space. This reduces the incompatibilities between neighboring grains and can favor twinning and thus increase the MFIS. This approach was validated recently with very large MFIS (0.2-8%) measured in Ni-Mn-Ga fibers and foams with bamboo grains with dimensions similar to the fiber or strut diameters and in thin plates where grain diameters are comparable to plate thickness. Here, we review processing, micro- and macrostructure, and magneto-mechanical properties of (i) Ni-Mn-Ga powders, fibers, ribbons and films with one or more small dimension, which are amenable to the growth of bamboo grains leading to large MFIS, and (ii) “constructs” from these structural elements (e.g., mats, laminates, textiles, foams and composites). Various strategies are proposed to accentuate this geometric effect which enables large MFIS in polycrystalline Ni-Mn-Ga by matching grain and sample sizes.

Size Effects on Magnetic Actuation in Ni-Mn-Ga Shape-Memory Alloys

Additive layer manufacturing (ALM), using gas tungsten arc welding (GTAW) as heat source, is a promising technology in producing Inconel 625 components due to significant cost savings, high deposition rate and convenience of processing. With the purpose of revealing how microstructure and mechanical properties are affected by the location within the manufactured wall component, the present study has been carried out. The manufactured Inconel 625 consists of cellular grains without secondary dendrites in the near-substrate region, columnar dendrites structure oriented upwards in the layer bands, followed by the transition from directional dendrites to equiaxed grain in the top region. With the increase in deposited height, segregation behavior of alloying elements Nb and Mo constantly strengthens with maximal evolution in the top region. The primary dendrite arm spacing has a well coherence with the content of Laves phase. The microhardness and tensile strength show obvious variation in different regions. The microhardness and tensile strength of near-substrate region are superior to that of layer bands and top region. The results are further explained in detail through the weld pool behavior and temperature field measurement.

Effect of location on microstructure and mechanical properties of additive layer manufactured Inconel 625 using gas tungsten arc welding

The effect of Fe content on hardness and toughness of Ni48.7Mn30.1−xFexGa21.2 (x = 0–11, number indicates at.%) alloys is investigated and the relationship between the fracture toughness and the fractography is discussed by observing the fracture morphology and analyzing the propagation of the crack. The micro-Vickers hardness results indicate that the hardness increases with increasing Fe content. The fracture toughness results indicate that Fe doping has improved the toughness of Ni–Mn–Ga alloys, and the toughness increases with increasing Fe content in Ni48.7Mn30.1−xFexGa21.2 (x = 0–11) alloys. Fracture morphology shows typical intergranular fracture with rock candy pattern in the Ni48.7Mn30.1Ga21.2 (x = 0) and river pattern cleavage fracture facets in the Ni48.7Mn19.1Fe11Ga21.2 (x = 11) alloy. The fracture type changing from intergranular fracture to transgranular fracture is the main reason for the improved toughness of Ni–Mn–Ga alloys by addition of Fe.

Effect of Fe content on fracture behavior of Ni–Mn–Fe–Ga ferromagnetic shape memory alloys

The temperature effect often significantly affects the performance of large-span spatial structure and even becomes one of the controlling loads. To obtain the non-uniform temperature field distribution of the thin-walled steel members under solar radiation and the influence rules of various factors, in this paper, experimental studies are carried out with three groups of specimens including rectangular steel tube, I-shaped steel and circular steel tube. Based on the test data, the non-uniform temperature field distributions considering the influence of solar radiation intensity, member size and surface coating are analyzed in detail. Then, numerical methods for the temperature field of steel members are studied considering multiple environmental factors. The validity of the numerical method is evaluated with test results. Finally, based on the parametrical studies of the major influence factors, a simplified calculation approach is presented for practical engineering applications. The experimental study demonstrates that the non-uniform temperature distribution of steel members truly exists and cannot be overlooked. The numerical method for the temperature field in this paper is effective, and the simplified calculation approach can meet the required engineering precision. The research methods and conclusions of this work can provide valuable references for thermal design, monitoring and control of steel structures.

Huajie Wang

Papers

Effect of location on microstructure and mechanical properties of additive layer manufactured Inconel 625 using gas tungsten arc welding

Effect of Fe content on fracture behavior of Ni–Mn–Fe–Ga ferromagnetic shape memory alloys

Experimental and numerical investigation on the non-uniform temperature distribution of thin-walled steel members under solar radiation

Effect of local corrosion on the axial compression behavior of circular steel tubes

Experimental and numerical investigation of temperature effects on steel members due to solar radiation