Abstract
Wire Arc Additive Manufacturing is a near-net-shape processing technology which allows the cost-effective manufacturing of big and customized metal parts. In the present work the Wire Arc Additive Manufacturing of AW4043/AlSi5(wt.%) with different lead angles of the welding torch was investigated. It has been shown that for some lead angles fluctuation effects occur in the structures produced if the interlayer temperature is either too low or too high. All experiments were analysed by high-speed imaging whereby the welding phenomena could be observed. In the case of Wire Arc Additive Manufacturing with a lead angle above 10° at lower interlayer temperatures, the deposited track consists out of several, seperated WAAM globules and is no longer in a uniform track. In the case of the dragging and neutral Wire Arc Additive Manufacturing processes at higher interlayer temperatures, fluctuation effects occur. In addition, by evaluating the high-speed videos with computer vision, it was found that such fluctuation effects can be detected at the arc frequency of the process. To avoid fluctuation effects caused by too low or too high interlayer temperatures, a pushing Wire Arc Additive Manufacturing process with a slightly tilted lead angle should be used.
Highlights
Wire Arc Additive ManufacturingWire Arc Additive Manufacturing (WAAM) is a near-net-shape processing technology that is classified as one of the Direct Energy Deposition (DED) processes [1,2]
Most Wire Arc Additive ManufacturingWire Arc Additive Manufacturing (WAAM) processes are based on Gas Metal Arc Welding, in particular the welding process Cold Metal Transfer (CMT) [4,5]
One parameter that affects the process stability, is the lead angle of the welding torch to the process zone which has previously been investigated for Gas Tungsten Arc Welding (GTAW) [17,18]
Summary
Wire Arc Additive Manufacturing (WAAM) is a near-net-shape processing technology that is classified as one of the Direct Energy Deposition (DED) processes [1,2]. Köhler et al figured out that the solidification range and the WAAM settings such as arc length and pulse energy have significant effects on surface waviness [28] They suggested that a wide solidification range is more suitable for a smooth track [28]. Ortega et al investigated WAAM of AlSi5(wt.%), a widely used welding alloy, and properties such as the microstructure of the resulting parts [4]. Miao et al investigated the microstructure and the mechanical properties of AlSi5(wt.%) manufactured by laser modified WAAM [31] They found out that the additional energy input from the laser beam leads to a microstructure with finer grains and to increased mechanical properties [31]. The object of the present work is multilayer processing using WAAM, considering the increasing interlayer temperatures and the related effects
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