Numerical Analysis and Experimental Verification of Resistance Additive Manufacturing

Suli Li,Laixia Yang,Kaiyue Ma,Chao Xu,Bingheng Lu

doi:10.3390/cryst12020193

Suli Li, Laixia Yang + Show 3 more

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https://doi.org/10.3390/cryst12020193

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Abstract

In recent years, scholars have proposed a metal wire forming method based on the Joule heat principle in order to improve the accuracy of additive manufacturing and reduce energy consumption and cost, but it is still in the theoretical stage. In this paper, a mathematical model of resistance additive manufacturing was established using finite element software, and the temperature variation of the melting process under different currents was analyzed. A suitable current range was preliminarily selected, and an experimental system was built. Through experimental study of the current and wire feeding speed, the influences of different process parameters on the forming appearance of the coating were analyzed. The results showed that the forming appearance was the best for Ti-6Al-4V titanium alloy wire with a diameter of 0.8 mm, when the current was 160 A, the voltage was 10 V, the wire feeding speed was 2.4 m/min, the workbench moving speed was 5 mm/s, and the gas flow rate was 0.7 m3/h. Finally, the process parameters were used for continuous single-channel multilayer printing, verified the feasibility of the process at the experimental level and provided reference data for the subsequent development of this technology.

Highlights

With the demand for high-performance, large, integrated, high-strength, and low-cost metal structural parts in the aerospace and automotive industries [1,2], metal additive manufacturing printing technology has become a hot topic for research and applications in additive manufacturing technology [3,4]
The raw materials of metal additive manufacturing technology can be divided into powder and wire [5]
With its advantages of high material utilization rate, high deposition rate, low cost, and low pollution, wire has been widely used in the field of metal additive manufacturing [6,7,8]

Summary

Introduction

With the demand for high-performance, large, integrated, high-strength, and low-cost metal structural parts in the aerospace and automotive industries [1,2], metal additive manufacturing printing technology has become a hot topic for research and applications in additive manufacturing technology [3,4]. With its advantages of high material utilization rate, high deposition rate, low cost, and low pollution, wire has been widely used in the field of metal additive manufacturing [6,7,8]. LAM has high forming accuracy, high flexibility, and a short manufacturing cycle [10], but has low energy utilization; the residual stress of the formed part is large, and the cost of the laser head is high [11]. WAAM and WPAM have the advantages of low cost and high deposition efficiency [15], but the process parameters of both are variable and complex, and the dimensional accuracy of the manufactured parts is not high [16,17]. Reducing manufacturing costs, improving forming accuracy and efficiency, and ensuring forming quality are of great significance to the widespread application of metal wire additive manufacturing technology

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Results

Conclusion