Journal ArticleDOI
Concept and validation of an active cooling technique to mitigate heat accumulation in WAAM
Leandro João da Silva,Leandro João da Silva,Danielle Monteiro Souza,Douglas Bezerra de Araújo,Ruham Pablo Reis,Américo Scotti,Américo Scotti +6 more
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TLDR
In this paper, a thermal management technique, named as near-immersion active cooling (NIAC), is proposed to mitigate heat accumulation in wire + arc additive manufacturing (WAAM).Abstract:
This work aimed at introducing and exploring the potential of a thermal management technique, named as near-immersion active cooling (NIAC), to mitigate heat accumulation in Wire + Arc Additive Manufacturing (WAAM). According to this technique concept, the preform is deposited inside a work tank that is filled with water, whose level rises while the metal layers are deposited. For validation of the NIAC technique, Al5Mg single-pass multi-layer linear walls were deposited by the CMT® process under different thermal management approaches. During depositions, the temperature history of the preforms was measured. Porosity was assessed as a means of analyzing the potential negative effect of the water cooling in the NIAC technique. The preform geometry and mechanical properties were also assessed. The results showed that the NIAC technique was efficient to mitigate heat accumulation in WAAM of aluminum. The temperature of the preforms was kept low independently of its height. There was no measurable increase in porosity with the water cooling. In addition, the wall width was virtually constant, and the anisotropy of mechanical properties tends to be reduced, characterizing a preform quality improvement. Thus, the NIAC technique offers an efficient and low-cost thermal management approach to mitigate heat accumulation in WAAM and, consequently, also to cope with the deleterious issues related to such emerging alternative of additive manufacturing.read more
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Journal ArticleDOI
Thermal management in WAAM through the CMT Advanced process and an active cooling technique
Fernando Matos Scotti,Felipe Ribeiro Teixeira,Leandro João da Silva,Douglas Bezerra de Araújo,Ruham Pablo Reis,Américo Scotti,Américo Scotti +6 more
TL;DR: In this paper, the authors proposed an evaluation of the CMT Advanced process combined with the NIAC technique for wire + arc additive manufacturing (WAAM) in order to mitigate heat accumulation and cope with limitations regarding deposition cycle, geometry issues and mechanical property anisotropies.
Journal ArticleDOI
WAAM system with interpass temperature control and forced cooling for near-net-shape printing of small metal components
TL;DR: In this article, a three-axis WAAM system capable of reliably printing small, near-net-shape metal objects is presented. But the main challenge addressed is the minimisation of shape distortions caused by excessive heat accumulation when printing small objects.
Journal ArticleDOI
Gas metal arc welding based additive manufacturing—a review
TL;DR: This review begins with the GMAW-AM procedure, performance capability, identification of factors affecting the deposition performance, and strategies adopted to overcome these issues, and several aspects such as mathematical modelling, optimization, key process parameters, and their combinations for a wide range of wire electrode material and percentage contributions are reviewed and depicted in detail.
Journal ArticleDOI
A high-performance WAAM process for Al–Mg–Mn using controlled short-circuiting metal transfer at increased wire feed rate and increased travel speed
TL;DR: In this paper, a high-performance controlled short-circuiting metal transfer process at a wire feed rate of 12m/min for wire arc additive manufacturing (WAAM) with an Al-Mg-Mn alloying system was developed.
Journal ArticleDOI
Reduction of Energy Input in Wire Arc Additive Manufacturing (WAAM) with Gas Metal Arc Welding (GMAW).
TL;DR: This study shows the results of systematically adjusted CTWD during WAAM of low-alloyed steel, showing an energy reduction of up to 40% could be implemented leading to an adaptation of geometrical and microstructural features of additively manufactured work pieces.
References
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Journal ArticleDOI
Additive manufacturing of metallic components – Process, structure and properties
Tarasankar Debroy,Huiliang Wei,J.S. Zuback,T. Mukherjee,John W. Elmer,John O. Milewski,Allison M. Beese,Alexander E. Wilson-Heid,Amitava De,Wei Zhang +9 more
TL;DR: A review of the emerging research on additive manufacturing of metallic materials is provided in this article, which provides a comprehensive overview of the physical processes and the underlying science of metallurgical structure and properties of the deposited parts.
Journal ArticleDOI
Additive manufacturing of metals
TL;DR: In this paper, the authors describe the complex relationship between additive manufacturing processes, microstructure and resulting properties for metals, and typical microstructures for additively manufactured steel, aluminium and titanium are presented.
Journal ArticleDOI
Wire + Arc Additive Manufacturing
Stewart W. Williams,Filomeno Martina,Adrian C. Addison,Jialuo Ding,Goncalo Pardal,Paul A. Colegrove +5 more
TL;DR: In this article, the benefits of non-destructive testing, online monitoring and in situ machining are discussed, and strategies on how to manage residual stress, improve mechanical properties and eliminate defects such as porosity are suggested.
Journal ArticleDOI
Wire-feed additive manufacturing of metal components: technologies, developments and future interests
TL;DR: In this paper, an in depth review of various process aspects of wire-feed additive manufacturing, including quality and accuracy of wirefeed AM processed components, is presented, and the overall objective is to identify the current challenges for wire feed additive manufacturing as well as point out the future research direction.
Journal ArticleDOI
Effect of inter-layer dwell time on distortion and residual stress in additive manufacturing of titanium and nickel alloys
TL;DR: In this paper, the accumulation of distortion during additive manufacturing (AM) of titanium and nickel base alloys is made as a function of changes in dwell time between the deposition of individual layers.