Open AccessJournal Article
Thermal efficiency of arc welding processes
John N. DuPont,Arnold R. Marder +1 more
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In this paper, a study was conducted on the arc and melting efficiency of the plasma arc, gas tungsten, gas metal arc, and submerged arc welding processes using A36 steel base metal, and the results were extended to develop a quantitative method for estimating weld metal dilution.Abstract:
A study was conducted on the arc and melting efficiency of the plasma arc, gas tungsten arc, gas metal arc, and submerged arc welding processes The results of this work are extended to develop a quantitative method for estimating weld metal dilution in a companion paper Arc efficiency was determined as a function of current for each process using A36 steel base metal Melting efficiency was evaluated with variations in arc power and travel speed during deposition of austenitic stainless steel filler metal onto A36 steel substrates The arc efficiency did not vary significantly within a given process over the range of currents investigated The consumable electrode processes exhibited the highest arc efficiency (084), followed by the gas tungsten arc (067) and plasma arc (047) processes Resistive heating of the consumable GMAW electrode was calculated to account for a significant difference in arc efficiency between the gas metal arc and gas tungsten arc processes A semi-empirical relation was developed for the melting efficiency as a function of net arc power and travel speed, which described the experimental data well An interaction was observed between the arc and melting efficiency A low arc efficiency factor limits the power delivered to the substrate which, in turn, limits the maximum travel speed for a given set of conditions High melting efficiency is favored by high arc powers and travel speeds As a result, a low arc efficiency can limit the maximum obtainable melting efficiencyread more
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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.
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Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice
TL;DR: In this article, a unified equation to compute the energy density is proposed to compare works performed with distinct equipment and experimental conditions, covering the major process parameters: power, travel speed, heat source dimension, hatch distance, deposited layer thickness and material grain size.
Journal ArticleDOI
Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)
Tiago A. Rodrigues,Valdemar R. Duarte,Rosa Maria Mendes Miranda,Telmo G. Santos,João Pedro Oliveira +4 more
TL;DR: 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.
Journal ArticleDOI
A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM)
TL;DR: In this paper, the tangent overlapping model (TOM) was proposed to model the geometry of multiple beads overlapping together in a wire and arc additive manufacturing (WAAM) process and the concept of critical centre distance for stable multi-bead overlapping processes was presented.
References
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Book
The Physics of Welding
TL;DR: In this paper, the authors describe electric arc welding, high energy density welding, and future developments of welding processes, and discuss the benefits of better understanding of the physics of welding.
Book
Transport Phenomena in Metallurgy
TL;DR: Transport phenomena in metallurgy as mentioned in this paper, Transport phenomena in METAL METAL, transport phenomena and metallurgical transport phenomena, METAL transport phenomena in the metallurgies.
Journal Article
Analysis of metal transfer in gas metal arc welding
Y.-S. Kim,Thomas W. Eagar +1 more
TL;DR: In this article, the static force balance theory and pinch instability theory as a function of welding current were used to predict the droplet sizes produced in GMAW using both the static forces balance theory (SFT) and the pinch instability (PIT) theory.