Abstract
The wire arc additive manufacturing (WAAM) process used to manufacture aluminum parts has a number of variables. This study focuses on the effects of the heat input and the current and voltage ratio on the deposition efficiency. The effects of the heat input and current and voltage ratio (V/A) on the bead geometry were analyzed, depending on the cross-sectional geometry of the deposition layers, for nine different deposition conditions. The deposition efficiency was also analyzed by analyzing the cross-sectional geometry of the thin-wall parts made of aluminum. The heat input range was about 2.7 kJ/cm to 4.5 kJ/cm; the higher the heat input, the higher the deposition efficiency. The maximum deposition efficiency achieved in this study was 76%. The current and voltage ratio was used to quantify the portion of voltage (V) in the total heat input (Q), and the effect on the bead geometry was analyzed. As the portion of voltage in the quasi heat input decreased by about 10%, it was found that the deposition efficiency was decreased by 1% to 3%.
Highlights
Additive manufacturing (AM), called 3D printing technology, provides 3D geometry by depositing various materials, such as metals, plastics, composites, polymer materials, ceramics etc., by inputting 3D-designed digital geometry information into a manipulator [1,2,3,4,5]
Figure showsfrom the geometry of a single bead and the cross-sectional geometry thinthe thin-wall parts3made the continuous deposition of single beads
In order to confirm the change in mechanical properties that may occur due to the difference in the current and voltage ratio and heat input, the most accessible hardness measurement experiment was performed
Summary
Additive manufacturing (AM), called 3D printing technology, provides 3D geometry by depositing various materials, such as metals, plastics, composites, polymer materials, ceramics etc., by inputting 3D-designed digital geometry information into a manipulator [1,2,3,4,5]. Metal-based AM technology is divided into four types depending on the heat source or processing method, among other factors, and is typically divided into powder bed fusion (PBF) and direct energy deposition (DED) technology, which use a laser heat source and metal powder [7]. Metal AM technology using a metal powder and a laser heat source has been optimized to achieve precise and complex geometry. Many studies in this area have been conducted because the properties of metal can be improved through a combination of metal powders and technology. Various geometries can be achieved and the properties of metal materials can be improved by the combination of powders, there are issues such as the deposition speed, product size limitations, high equipment cost and deposition materials (powders). Powder metal 3D printing technology has been applied to parts with a small special ability so far, and its application to large parts is limited [8,9]
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