Enhancing wire arc additive manufacturing in vibrational environments with longitudinal magnetic fields

Abstract

To enhance the appearance and mechanical properties of Wire Arc Additive Manufacturing (WAAM) specimens within a vibrational environment, this study systematically investigated the forming process and results of ER50-6 steel deposition under external longitudinal magnetic field conditions. The research revealed that applying an appropriately longitudinal magnetic field significantly improved the appearance quality of the formed specimens, particularly under low vibration conditions, with optimized magnetic field parameters at a current of 0.95 A demonstrating prominent effects. The introduction of the longitudinal magnetic field effectively constrained the arc, imparting higher stability. Moreover, the magnetic field accelerated droplet transitions, reducing the occurrences of large droplets and short-circuit transitions, resulting in smoother droplet transitions. However, in high vibration environments, finding a magnetic field of suitable strength for substantial improvement proved challenging due to the influence of vibrational inertial forces. Finally, the introduction of the longitudinal magnetic field refined the grain structure and improved the tensile strength, yield strength and elongation of the samples, reaching 470 MPa, 358 MPa and 31.2%, respectively.