Abstract
In the present study, the gas tungsten arc welding wire feed additive manufacturing process is simulated and its final microstructure predicted by microstructural modelling, which is validated by microstructural characterization. The Finite Element Method is used to solve the temperature field and microstructural evolution during a gas tungsten arc welding wire feed additive manufacturing process. The microstructure of titanium alloy Ti-6Al-4V is computed based on the temperature evolution in a density-based approach and coupled to a model that predicts the thickness of the α lath morphology. The work presented herein includes the first coupling of the process simulation and microstructural modelling, which have been studied separately in previous work by the authors. In addition, the results from simulations are presented and validated with qualitative and quantitative microstructural analyses. The coupling of the process simulation and microstructural modeling indicate promising results, since the microstructural analysis shows good agreement with the predicted alpha lath size.
Highlights
The Gas Tungsten Arc Welding (GTAW) wire feed additive manufacturing (AM) process involves the deposition of metal material using a tungsten arc as an energy source
GTAW belongs to the group of Direct Energy Deposit (DED) methods in the family of AM processes
A solid metal wire is fed through a conventional wire feeder and deposited layer-by-layer onto a substrate
Summary
The Gas Tungsten Arc Welding (GTAW) wire feed additive manufacturing (AM) process involves the deposition of metal material using a tungsten arc as an energy source. For the industry to the required properties andmanufacturing, support the development and understanding of theparts manufacturing process fully adopt additive and to be able to qualify titanium for aerospace a complete understandinga of the mechanical behavior andincontrol of the resulting itself.applications, Finite Element (FE) simulations, conventional method used the modeling of welding properties are prerequisites. Cumbersome if a large component is to be simulated It facilitates the future combination of the microstructural withneeds, a mechanical model pragmatic to use a density type of model, called the internal state variable approach by Grong to compute material properties. The aim of the present study has been to, for the first time, couple the process simulation model, on a larger scale It facilitates the future combination of the microstructural model with a developed by the authors [4], with a microstructural model, which has been developed by the mechanical model to compute material properties. Results were validated by building a well-defined, 10-layer-high weld sequence, in which, at specific positions, its
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