A THERMAL MODEL FOR WIRE ARC ADDITIVE MANUFACTURING
DOI:
https://doi.org/10.17770/etr2023vol3.7212Keywords:
WAAM, modelling, thermal task definition, heat source calibrationAbstract
Layer-by-layer detailing processes, which used wire and electric arc - wire arc additive manufacturing (WAAM), are among the most productive in 3D metal printing technologies. From this point of view, the solution of the thermal task, and subsequently of the deformation problem, are particularly relevant. It is natural that these simulation modelling processes are closely related to welding, but at the same time it is necessary to take into account particularities that are crucial for WAAM and are not always relevant in welding. In this research, one such model is proposed, which takes into account the gradual filling of the working space with the deposited metal. The specific issues related to the construction of the model, the definition of the heat source and the first layer formation in the conditions of WAAM are considered. The obtained numerical results enable the prediction of the layer dimensions.
Downloads
References
T. A. Rodrigues, V. Duarte, R.M. Miranda, T. G. Santos and J. P. Oliveira, ”Current status and perspectives on wire and arc additive manufacturing (WAAM)”, Materials vol.12, issure 7, art. ID 1121, 2019.
K. Barath and M. Manikandan, “Assessment of process, parameters, residual stress mitigation, post treatments and finite element analysis simulations of wire arc additive manufacturing technique”, Metals and Materials International, vol. 28, pp.54-111, 2022.
V. Mishra, A. Babu, R Schreurs, U. Wu, M Hermans and C. Ayas, “Microstructure Estimation and Validation of ER110S-G steel structures produced by Wire and Arc Additive Manufacturing”, Journal of Materials Research and Technology, vol. 23, pp. 3579-3601, 2023
T. Zhang, H. Li, H. Gong, Y. Wu, X. Chen and X. Zhang, ”Study on location-related thermal cycles and microstructure variation of additively manufactured inconel 718”, Journal of Materials Research and Technology, vol. 18, pp. 3056-3072, 2022.
J. Xiaolei, X. Jie, L. Zhaoheng, H. Shaojie, F. Yu and S. Zhi, “A new method to estimate heat source parameters in gas metal arc welding simulation process”, Fusion Engineering and Design vol. 89, pp. 40– 48, 2014
T. Mukherjee, W. Zhang and T. DebRoy, “An improved prediction of residual stresses and distortion in additive manufacturing”, Computational Materials Science vol. 126 pp. 360–372, 2017
H. Arora, R. Singh and G.S. Brar, “Thermal and structural modelling of arc welding processes: A literature review”, Measurement and Control, vol 52 (7-8), pp. 955-969, 2019, SAGE Publications Sage UK: London, England
N.P. Gokhale and P. Kala “Thermal analysis of TIG-WAAM based metal deposition process using finite element method” ,Materials Today: Proceedings, vol. 44, pp. 453-459, 2021.
C. Xiaoxuan, S. Xin, Z. Zirong and S. Chen, “A Review of the Development Status of Wire Arc Additive Manufacturing Technology”, Advances in Materials Science and Engineering Volume 2022, Article ID 5757484, 28 pages https://doi.org/10.1155/2022/5757484
S. Pattanayak and S.K. Sahoo; “Gas metal arc welding based additive manufacturing - a review”, CIRP Journal of Manufacturing Science and Technology, vol. 33, pp. 398-442, 2021.
M. Chaturvedi, E. Scutelnicu, C.C. Rusu, L.R. Mistodie, D. Mihailescu and A.V. Subbiah; “Wire arc additive manufacturing: Review on recent findings and challenges in industrial applications and materials characterization”, Metals, vol. 11, issure 6, art. ID 939, 2021.
W.C. Ke, J.P. Oliveira, B.Q. Cong, S.S. Ao, Z.W. Qi, B. Peng and Z. Zeng,; “Multi-layer deposition mechanism in ultra high-frequency pulsed wire arc additive manufacturing (WAAM) of NiTi shape memory alloys”, Additive Manufacturing, vol. 50, art. ID 102513, 2022
X. Chen, C. Wang, J. Ding, P. Bridgeman and S. Williams, “A three-dimensional wire-feeding model for heat and metal transfer, fluid flow, and bead shape in wire plasma arc additive manufacturing”,Journal of Manufacturing Processes, vol. 83, pp. 300-312, 2022.
X. Zhou, H. Zhang, G. Wang and X. Bai, “Three-dimensional numerical simulation of arc and metal transport in arc welding based additive manufacturing”, International Journal of Heat and Mass Transfer vol.103, pp. 521–537, 2016
F. Hejripour, D. T. Valentine and D. K. Aidun, “Study of mass transport in cold wire deposition for Wire Arc Additive Manufacturing”, International Journal of Heat and Mass Transfer vol. 125, pp. 471–484, 2018.
X. Bai, P. Colegrove, J. Ding, X. Zhou, C. Diao, P. Bridgeman, J. Hönnige, H. Zhang and S. Williams, “Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing”, International Journal of Heat and Mass Transfer vol. 124 pp. 504–516, 2018
W. Ou et al. “Fusion zone geometries, cooling rates and solidification parameters during wire arc additive manufacturing”, International Journal of Heat and Mass Transfer vol. 127, pp. 1084-1094, 2018
W. Ou et al. “Determination of the control points for circle and triangle route in wire arc additive manufacturing (WAAM)”, Journal of Manufacturing Processes vol. 53, pp. 84-98, 2020.
S. Suryakumar, K.P. Karunakaran, Alain Bernard, U. Chandrasekhar, N. Raghavender and D. Sharma, “Weld bead modeling and process optimization in Hybrid Layered Manufacturing”, Computer-Aided Design vol. 43, pp. 331–344, 2011
L. Nguyen, J. Buhl, and M. Bambach. “Multi-bead overlapping models for tool path generation in wire-arc additive manufacturing processes.” Procedia Manufacturing vol. 47, pp. 1123-1128, 2020
J. Xiong, G. Zhang, H. Gao and L. Wu, “Modeling of bead section profile and overlapping beads with experimental validation for robotic GMAW-based rapid manufacturing”, Robotics and Computer-Integrated Manufacturing vol. 29 issure 2, pp. 417-423, 2013
D. Ding, Z. Pan, D. Cuiuri and H. Li, “A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM)”, Robotics and Computer-Integrated Manufacturing vol. 31, pp. 101-110, 2015
B. Tomar, S, Shiva and T. Nath, “A review on wire arc additive manufacturing: Processing parameters, defects, quality improvement and recent advances”, Materials Today Communications, vol. 31 art. ID 103739, 2022
P. Shukla, B. Dash, D.V. Kiran and S Bukkapatnam, “Arc behavior in wire arc additive manufacturing process”, Procedia Manufacturing, vol. 48, pp. 725-729, 2020.
M. Benakis, D. Costanzo and A. Patran, “Current mode effects on weld bead geometry and heat affected zone in pulsed wire arc additive manufacturing of Ti-6-4 and Inconel 718”, Journal of Manufacturing Processes vol. 60, pp. 61–74, 2020.
V. A Hosseini et al. “Wire-arc additive manufacturing of a duplex stainless steel: thermal cycle analysis and microstructure characterization” Welding in the World vol. 63 pp. 975-987, 2019.
R. Israr, J. Buhl, L. Elze and M. BamBach “Simulation of different path strategies for wire-arc additive manufacturing with Lagrangian finite element methods”, LS-DYna Forum. 2018, Bamberg.
C.S. Wu and L. Dorn, “Computer simulation of fluid dynamics and heat transfer in full-penetrated TIG weld pools with surface depression”, Computational Materials Science vol 2q issure 2, pp. 341-349, 1994
L. Nguyen, J. Buhl, R. Israr and M. Bambach, “Analysis and compensation of shrinkage and distortion in wire-arc additive manufacturing of thin-walled curved hollow sections”, Additive Manufacturing vol. 47, art. ID 102365, 2021.
X. Meng, G. Qin amd Z. Zou, “Sensitivity of driving forces on molten pool behavior and defect formation in high-speed gas tungsten arc welding”, International Journal of Heat and Mass Transfer vol. 107, pp. 1119–1128, 2017.
