Arc Additive Manufacturing Research Articles

Wire arc additive manufacturing NiTi/Nb bionic laminated heterogeneous structure: Microsturcture evolution and mechanical properties

In the aerospace industry and the medical field, there is a demand for materials that combine the functional properties of NiTi with the excellent ductility of Nb. However, creating high-strength interfaces between these two materials has been difficult due to their inherent differences in physical and chemical properties. In this study, a laminated heterogeneous structure (LHS) combining NiTi and Nb was prepared using wire arc additive manufacturing (WAAM) with different layer thickness ratios. The resulting microstructure of the NiTi/Nb LHS components consisted of a large amount of NiTi and β-Nb eutectic structures. This was due to the metallurgical bonding between the NiTi and Nb layers. The NiTi/Nb LHS components exhibited excellent compressive strength, measuring at 2607.6 ± 31 MPa. Additionally, the interface strength of the NiTi/Nb LHS component was remarkable, showing an ultimate tensile strength of 789.3 ± 8 MPa. The enhanced strength of the NiTi/Nb LHS component can be attributed to the gradient microstructure of the NiTi layer, which promoted heterogeneous plastic deformation generation. Furthermore, this study unveiled the relationship between the formation mechanism of the heterogeneous eutectic microstructure and the strength-ductility synergistic mechanism. As a result, this study provides an innovative approach for additive manufacturing in the strengthening of laminated multi-material interfaces.

Influence of post heat treatment on tribological and microstructural properties of plasma wire arc additive manufactured maraging steels

Abstract Metallic alloys are increasingly being produced using wired arc additive manufacturing (WAAM). In this study, 18Ni300 defect-free maraging steels were produced using the WAAM technique. A traditional solution treatment, direct aging, and cryogenic heat treatment processes were applied to the WAAM produced maraging steels. The influence of conventional and novel cryogenic heat treatments on microstructural, mechanical, and tribological properties were examined. The microstructure of the as-built materials obtained by WAAM thermal cycling has mainly been homogenized through the solution, direct-aging, and cryogenic heat treatments. As a result, homogeneously distributed precipitate phases were obtained and the hardness increased by 30 % with a combination different post heat treatments. The cryogenic heat treatment improved the martensitic transformation and facilitated the formation of various Fe–Ni–Mo–Ti-containing intermetallic precipitates. Similarly, because of the different heat treatments, the wear resistance improved by a factor of 2–5.5 relative to the as-built material. Adding the cryogenic heat treatment to the traditional heat treatment procedure improves wear resistance by a factor of 1.2–2.9.

In Situ Pre-heating in Wire Arc Additive Manufacturing: Design, Development, and Experimental Investigation on Residual Stresses and Metallurgical and Mechanical Properties

In Situ Pre-heating in Wire Arc Additive Manufacturing: Design, Development, and Experimental Investigation on Residual Stresses and Metallurgical and Mechanical Properties

Machine Learning Approach for Predicting Bead Geometry of Stainless Steel in Wire arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) employs an electric arc to melt wire feedstock, making it a method within additive manufacturing (AM). It deposits material layer by layer to build up a part. The present study investigated the application of machine learning classification-based models for estimating bead width and bead height of stainless-steel parts fabricated using WAAM. The input parameters (voltage, current, wire feed rate, and travel speed) were considered as input to algorithms. Training and testing were performed for 98 experimental data sets from peer-reviewed literature. The machine learning classification models, K-nearest neighbors, decision tree with gini index as criteria, and random forest were evaluated. The ML model performance was evaluated utilizing statistical metrics, including accuracy, F1 score, precision, and recall. The decision tree classifier exhibited the highest accuracy of 87.8% for bead width and 84.7% for bead height. The findings offer valuable insights into leveraging ML techniques to enhance the performance and accuracy of predictive models within WAAM-based AM.

Oxidation kinetics of Ti6Al4V alloy deposited by wire arc additive manufacturing using argon gas as processing atmosphere

Ti6Al4V alloy is currently the most common metal alloy of the α+β phase type, its application is increasing as it has excellent properties at elevated temperatures. The main users of Ti6Al4V alloy are industries like of aerospace, naval, and biomedical; therefore, Ti6Al4V alloys one of the most studied material worldwide. One of the great advantages that Ti6Al4V alloy offers is the possibility of manufacturing components in situ by means of additive technologies.. Similar studies, in additive manufacturing, have reported the formation of titanium oxide on the surface of the material, followed by an oxygen-enriched region called "α-case". By means of thermogravimetric analysis, the oxidation effect on the surface of Ti6Al4V samples, obtained by wire arc additive manufacturing as well as samples from conventional manufacture, were studied. Argon gas, with an oxygen partial pressure of 1x10-5 atm, was used as the oxidation atmosphere within a range of 550°C to 950°C and oxidatión times of 60 min and 180 min. For the oxidation reaction, the kinetic analyses led to calculate the activation energy as 250 kJ/mol and 166 kJ/mol for the Ti6Al4V alloy processed by conventinal and additive manufacturing, respectively. The results of the of thermogravimetric analysis were fitted to a parabolic-type kinetic model. Furthemore, a mathematical model was proposed to predict the oxidation kinetics. The experimental data were fitted to the mathematical model in the range of 750 - 950°C for Ti6Al4V alloy by wire arc additive manufacturing. The oxidized microstructures were analized by optical and electronic microscopy finding α-case on the surface of the samples.

Experimental Investigations on the Fabrication of Low Alloy Steels Using Wire Arc Additive Method

Wire arc additive manufacturing (WAAM) has emerged as a transformational technology with the capacity to redefine the landscape of alloy steel component production. This method utilizes an electric arc to selectively fuse a continuous wire feed, progressively constructing intricate metal structures layer by layer. GMAW-based WAAM adaptability enables the creation of complex geometries and customized part designs, making it applicable across diverse industrial sectors. This paper investigates WAAM-specific applications in alloy steel fabrication, focusing on key process variables such as voltage, travel speed, and Gas mixture ratio. The experimental parameters for a single layer are examined with voltage ranging from 20 to 22, travel speed from 23, 25, and 27 mm/min, and Gas mixture ratio 1,5,9 mm/min. It utilizes materials like TM B9, a 1.2- diameter flux-cored wire. Additionally, the study considers the nominal composition (wt-%) of 9 Chromium, and 1 Molybdenum, with small additions of nitrogen and niobium to improve the creep resistance. Furthermore, the final findings of the study suggest that the optimal combination of process variables for achieving highquality weld beads in WAAM of alloy steel components can be determined through Response Surface Methodology (RSM). RSM is a statistical method for analysing and modeling the relationship between the response of interest and some independent variables. In this case, the response variable would be the quality of the weld bead, which encompasses factors such as bead geometry, integrity, and absence of defects.

Microstructural Analysis and Preliminary Wear Assessment of Wire Arc Additive Manufactured AA 5083 Aluminum Alloy for Lightweight Structures

The proliferation of Wire Arc Additive Manufacturing (WAAM) has significantly enhanced the production capabilities for lightweight and structurally robust components. This study investigates the microstructural characteristics, tensile properties, and preliminary wear performance of AA 5083 aluminum alloy processed via WAAM, focusing on applications for lightweight structures. Using SEM and XRD, microstructural changes during the WAAM process are analyzed, and tensile testing evaluates the mechanical properties, including ultimate tensile strength (UTS) and elongation. The results reveal that the microstructure consists of α-Al and β-(Al5Mg8) phases, with the Al5Mg8 phase distributed along grain boundaries and within grains. Notably, the grain size in the Y-direction (building direction) is larger than in the X-direction (deposition direction) due to temperature variations during processing. Tensile testing shows that horizontal samples (X-direction) have a UTS of 295 ± 5 MPa and elongation of 20.08 ± 0.8%, while vertical samples (Y-direction) have a UTS of 267 ± 10 MPa and elongation of 16.43 ± 2.1%. This results in an anisotropy of 9.4% in tensile strength, reflecting the differences in mechanical properties between the two directions. The WAAM AA 5083 aluminum part exhibits a maximum wear rate of 5.22 × 10⁻³ mm³/m and a coefficient of friction of 0.52 at a load of 3.5 kg and 450 rpm. Under these conditions, deep grooves, layer separation, and load-induced deformation are observed. The primary wear mechanisms include delamination, adhesion, and abrasion. Hardness levels are consistent in the X-direction and show minimal variance in the Y-direction, with an average hardness of 89.4 ± 5.14 HV0.5. The study demonstrates that WAAM-produced AA 5083 aluminum alloy, with an anisotropy below 10%, is suitable for real-time lightweight structures, offering effective performance in engineering applications such as aerospace and automotive industries. Future research should focus on further quantifying wear behavior and optimizing processing conditions to enhance material performance for specific applications.

Ultrasonic evaluation of wire arc additively manufactured parts with heterogeneous microstructure

Abstract In Wire Arc Additive Manufacturing (WAAM) components manufactured by gas metal arc welding strategy, periodically alternating patterns of fine- and coarse-grained microstructures develop along the building direction, depending on the temperature evolution. Ultrasonic non-destructive evaluation relies on the scattering of waves from defects. In the material microstructure, ultrasound waves are also scattered at the grain boundaries as grain noise. The work presents a study on the influence of heterogeneous microstructure in WAAM on defect detectability during ultrasonic inspections. The study used a 2D finite element model to simulate ultrasound wave propagation in the material microstructure represented by a surface element from electron backscatter diffraction scans. Side-drilled holes were introduced in the material as defects. Phased array was used to perform full matrix capture and obtain ultrasound image through total focusing method, with dynamic focusing capability to inspect the heterogeneous microstructure. The study analysed the defect echoes and noises using the signal-to-noise ratio (SNR) to assess its defect detectability. While defects were well detected, the SNR values differ by 10% for defects at various positions along the building and transverse directions in the heterogeneous microstructure.

Prediction of Failure Due to Fatigue of Wire Arc Additive Manufacturing-Manufactured Product

Currently, the focus of production is shifting towards the use of innovative manufacturing techniques and away from traditional methods. Additive manufacturing technologies hold great promise for creating industrial products. The industry aims to enhance the reliability of individual components and structural elements, as well as the ability to accurately anticipate component failure, particularly due to fatigue. This paper explores the possibility of predicting component failure in parts produced using the WAAM (wire arc additive manufacturing) method by employing fractal dimension analysis. Additionally, the impact of manufacturing imperfections and various heat treatment processes on the fatigue resistance of 30CrMnSi steel has been investigated. Fatigue testing of samples and actual components fabricated via the WAAM process was conducted in this study. The destruction of the examined specimens and products was predicted by evaluating the fractal dimensions of micrographs acquired at different stages of fatigue testing. It has been established that technological defects are more dangerous in terms of fatigue failure than microstructural ones. The correctly selected mode of heat treatment for metal after electric arc welding allows for a more homogeneous microstructure with a near-complete absence of microstructural defects. A comparison of the fractal dimension method with other damage assessment methods shows that it has high accuracy in predicting part failure and is less labor-intensive than other methods.

Effect of heat treatment on the microstructure and mechanical properties of 18Ni 300 maraging steel manufactured by wire + arc additive manufacturing

ABSTRACT A thin-walled structure was manufactured by wire + arc additive manufacturing using 18Ni 300 maraging steel, and the heat treatment process had been investigated. The microstructure of as-deposited sample was martensite, ferrite and nano-precipitated phases. Differently, more nano-precipitated phases and reverted austenite existed in the direct aging (AT) sample. However, only lath martensite and nano-precipitated phases existed in the solution + aging (SAT) sample. The as-deposited and AT samples performed a high strength with well plastic. The primary strengthening mechanism for this great improvement of tensile strength arose by the formation of nano-precipitated phases, which was known as the Orowan strengthening mechanism. The well plastic of as-deposited and AT samples was attributed to dual phase net basket sub-structures, which were beneficial to improve the length of crack propagation and the ability of cooperative deformation. And the reverted austenite was also main factor for the well plastic of the AT samples.

The effect of thermal cycle on microstructure evolution and mechanical properties of Co-free maraging steel produced by wire arc additive manufacturing

Microstructures and mechanical properties are closely related to thermal cycles during additive manufacturing. For maraging steel, the research on the effect of thermal cycles during additive manufacturing is limited. Based on the above issues, this work investigated the effect of thermal cycles in the process of wire arc additive manufacturing Co-free maraging steel on microstructure evolution and mechanical properties, and attempted to establish the relationship between thermal cycles and microstructure as well as mechanical properties of maraging steel on the basis of quantitative thermal cycle data. The results show that in the additive manufacturing process, the thermal cycles affect the cooling rate, so that the primary dendrite arm spacing and grain size gradually increase along the height direction. For maraging steel, in additive manufacturing, welding or other hot processing processes, the thermal cycles make the martensite reverse change, resulting in an increase in austenite content, resulting in grain refinement. Thermal cycles in additive manufacturing result in differences in the grain size, grain boundary ratio, dislocation density and primary dendrite arm spacing, resulting in inhomogeneity of the mechanical properties in the height direction. The difference in microstructure in different directions of additive manufacturing samples leads to anisotropy of tensile properties. The results of this work can elucidate and refine the action mechanism of thermal cycles on maraging steel. In addition, this work can be used to control thermal cycles by changing the process and cooling conditions, etc., to obtain maraging steel samples with homogeneous or gradient properties, which is highly important.

Investigating the effect of path planning strategies on 3D metallic structure deposited using robotic WAAM

Wire Arc Additive Manufacturing (WAAM) is an advanced technique for producing medium-to-large-sized components, offering high deposition rates and low equipment costs. Path planning strategies are critical in determining grain growth direction and achieving isotropic properties in the components. This study introduces a novel path planning strategy, the switchback mode, to mitigate unidirectional grain growth and enhance the mechanical properties of WAAM-deposited components. ER-4043 aluminium alloy walls were deposited using the switchback mode and compared with the conventional bi-directional path planning strategy. The findings reveal that different path planning strategies result in variations in layer size, surface morphology, microstructure, residual stress, microhardness, wear resistance, and tensile properties. Notably, the switchback mode demonstrated superior mechanical strength compared to the bi-directional mode, with yield strength (YS) increasing from 90.2 MPa to 113.9 MPa, ultimate tensile strength (UTS) from 148.8 MPa to 178.7 MPa, and elongation percentages from 18.4 % to 21.3 %. Furthermore, the residual stress changed from tensile to compressive when switching from bi-directional to switchback mode.

A novel heterogeneous particle addition method based on laser cladding hybrid wire arc additive manufacturing: improvement performance of stainless steel components

ABSTRACT The direct preparation of large components by laser cladding (LC) is not economical, but if it is used as a means of trace element addition and combined with the high efficiency advantages of wire arc additive manufacturing (WAAM), efficient manufacturing and high degree of freedom design of components can be achieved. In this study, high toughness and high plasticity stainless steel components were successfully prepared by combining WAAM and LC. The microstructure in the hybrid deposited specimens evolved into a single austenite, and the proportion of cubic and {001}<100 > textures increased. The mechanical properties obtained were significantly greater than those recommended for use by ASTM A479. The toughness of the hybrid deposited specimens was significantly improved, with a maximum increase in yield strength of 32%, exceeding 350 MPa. The elongation increased by a maximum of 12.7%, reaching 89.2% in the horizontal direction.

Effects of Longitudinal Alternating Magnetic Field on the Microstructure and Properties of CMT-WAAM Al-5%Mg Alloy

The major challenges in wire arc additive manufacturing (WAAM) of aluminum alloys include improving the forming quality, reducing pore and crack defects, and optimizing the overall mechanical properties. In this study, an external longitudinal alternating magnetic field (LAMF) was applied to assist cold metal transfer (CMT) WAAM process of Al-5%Mg alloy. This study compared the effects of different LAMF intensity parameters on the electrical behavior, molten droplet transition, macroscopic forming, microstructure and mechanical properties of CMT-WAAM multi-layer thin-walled structures. Compared with the situation without the alternating magnetic field, the application of an external LAMF could cause the arc to expand and rotate, deflect droplets and stir the molten pool periodically. When the alternating magnetic field parameters were set at a current of 3A and frequency of 100Hz with magnetic field intensity of 9mT, the deposited samples achieved macroscopic forming with superior surface quality and geometric accuracy, and the internal defect rate was reduced from 0.742% to 0.168%. Also, the mean grain size of the deposited layer was reduced from 186μm to 154μm, and the average hardness was increased from 68.1HV0.2 to 91.1HV0.2 with an improvement rate of 33.7%. Moreover, the longitudinal tensile strength was increased from 249 MPa to 257 MPa, the transverse tensile strength was increased from 264 MPa to 273 MPa, and the yield strength and elongation at break were both increased. This study demonstrates theoretical guidance for enhancing the component overall performance of aluminum alloy LAMF-WAAM technology.

Machine learning-assisted wire arc additive manufacturing and heat input effect on mechanical and corrosion behaviour of 316 L stainless steels

Predicting the track forming factor or height-to-width ratio (H/W) in wire arc additive manufacturing is crucial for optimal path planning, heat distribution, structural integrity, distortion control, process efficiency, and defect prevention, ensuring high-quality and reliable components. Different analytical and numerical modeling methods have been introduced to predict the H/W ratio. However, the accuracy of these predictions is relatively low due to the challenges associated with handling complex and non-linear regression equations. This study addressed the challenges by implementing data-driven predictive modeling to predict the H/W ratio from the input process parameters. A stacking ensemble learning approach is employed, where a meta-model integrates predictions from multiple base learners to enhance overall performance. The model performance was evaluated by Coefficient of determination (R2), mean squared error (MSE), and mean absolute error (MAE). The model was validated by comparing the experimental and predicted values based on which five thin walls are printed with different heat inputs. The study also explores the impact of heat input on microstructure, mechanical, and corrosion properties. The findings indicate that a significantly low heat input (178 J/mm) and higher heat inputs (> 356 J/mm) decrease the wire utilization. With increasing heat input, ferrite content increases, microstructures become coarser, dendritic spacing increases, and ferrite transitions from lathy to skeletal. Further, lower heat input (235 J/mm) reduces δ-ferrite, suppresses atomic segregation, and increases Cr and Mo in the matrix. YS and UTS decrease with higher heat inputs, anisotropy decreases, and Vickers microhardness drops from 228 (178 J/mm) to 194 Hv (586 J/mm). Additionally, the corrosion resistance deteriorates with increasing heat input, as evidenced by higher pitting potential (Epit: 0.389 V vs. 0.368 V vs. −0.023 V) and lower corrosion current density (Icorr: 6.76 ×10−7 A/cm2 vs. 7.946 ×10−7 A/cm2 vs. 8.91 ×10−7 A/cm2) for heat inputs of 235 J/mm, 281 J/mm, and 356 J/mm, respectively.

Anisotropic piezomagnetic behavior of wire and arc additively manufactured low carbon steel

The objective of this study is to investigate the piezomagnetic behavior corresponding to the mechanical properties of a low-carbon steel fabricated by wire arc additive manufacturing (WAAM) under tensile stress. WAAM rectangular tubes with a nominal thickness of 4 mm were fabricated with ER70S-6 wires using a continuous path with single way stacking between layers. Tests were carried out on WAAM steel specimens with three different orientations relative to the deposition direction extracted from rectangular tubes, and the evolutions of magnetic field around the specimens were recorded. The variation characteristics of piezomagnetic response at different loading stages were analyzed, highlighting the anisotropic nature of the piezomagnetic field evolution. The internal correlation between piezomagnetic field and tensile stress was explored. It is found that the piezomagnetic behavior of WAAM steel during the tensile process corresponds to the mechanical response. The Villari reversal points can be used to predict the yield strength and tensile ultimate strength of WAAM steel, and the area of the magnetic field-stress curve may be a measure of the ductility of WAAM steel. The theory of microscopic magnetic domains and the constitutive relation of ferromagnetic materials considering magnetocrystalline anisotropy were used to explain the experimental results. This study provides new insights into the anisotropic piezomagnetic properties of WAAM steel, offering potential applications in non-destructive evaluation of mechanical performance.

A review of wire and arc additive manufacturing using different property characterization, challenges and future trends

A review of wire and arc additive manufacturing using different property characterization, challenges and future trends

Strength-ductility synergy in a non-equiatomic Co–Cr–Ni medium entropy alloy wall structure deposited using twin-wire arc additive manufacturing

An innovative twin-wire arc additive manufacturing (T-WAAM) has been deployed to fabricate a Co-rich non-equiatomic Co–Cr–Ni medium entropy alloy. The TWAAM-built single-wall structures of Co50Cr10Ni40 alloy were fabricated under argon gas shielding using dual gas metal arc welding sources. The microstructure studies revealed a single-phase FCC crystal structure and defect-free deposition. The slender columnar substructure and cellular substructure are formed along the build direction (BD) and scan direction (SD) respectively, which are commonly observed in the wall structures of other conventional FCC alloys. The tensile coupon SD and BD displayed a superior high strength and ductility combination. The T-WAAM-fabricated Co50Cr10Ni40 alloy showed both strength and elongation 1.4 times greater than that of the laser additive manufactured equiatomic CoCrNi wall structure. Thus, the study opens up a new avenue to tailor the mechanical properties of CoCrNi MEA by composition variation, with an added advantage of higher deposition rates of TWAAM.

Investigation on the effects of deposition strategy on the mechanical characteristics and microstructure of austenitic stainless steel 308LSi manufactured via wire arc additive manufacturing

This study examines the impact of deposition strategy on ASS 308LSi thin-walled structure manufactured via the Wire Arc Additive Manufacturing (WAAM) technique on the microstructural characteristics, tensile strength, microhardness, Charpy impact testing, and fracture morphology of the WAAM 308LSi. The analysis of the microstructure reveals that the deposition strategy promotes transitioning from columnar to equiaxed fine grain structure. The tensile strength results show that specimens with a 45° deposition strategy exhibit lower anisotropy and higher tensile properties compared to those with a 0° deposition strategy, with improvements of 33.1% in the transverse direction and 26.7% in the longitudinal deposition directions, respectively. The microhardness in WAAM SS308LSi demonstrates variations in the bottom, middle, and top regions, with the highest average value observed at a 45° deposition strategy (213.3 ± 6.5 HV, 201.1 ± 10.7 HV, and 191.5 ± 5.2 HV) as well. The impact testing results indicate that the highest absorbed energy occurs at a 45° deposition strategy, with 75 ± 4.2 J and 74 ± 4.0 J for the transverse and longitudinal directions, respectively. The fractures observed during testing exhibit ductile characteristics, with the presence of dimples and particles. This study demonstrates the significant potential of the 45° deposition strategy with the implementation of double-sided substrate deposition, resulting in a refined microstructure, nearly isotropic behavior, and excellent mechanical performance.

Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys

It is difficult for traditional aluminum alloy manufacturing technology to meet the requirements of large-scale and high-precision complex shape structural parts. Wire Arc additive manufacturing technology (WAAM) is an innovative production method that presents the unique advantages of high material utilization, a large degree of design freedom, fast prototyping speed, and low cast. As a result, WAAM is suitable for near-net forming of large-scale complex industrial production and has a wide range of applications in aerospace, automobile manufacturing, and marine engineering fields. In order to serve as a reference for the further development of WAAM technology, this paper provides an overview of the current developments in WAAM both from the digital control system and processing parameters in summary of the recent research progress. This work firstly summarized the principle of simulation layering and path planning and discussed the influence of relative technological parameters, such as current, wire feeding speed, welding speed, shielding gas, and so on. It can be seen that both the welding current and wire feeding speed are directly proportional to the heat input while the travel speed is inversely proportional to the heat input. This process regulation is an important means to improve the quality of deposited parts. This paper then summarized various methods including heat input, alloy composition, and heat treatment. The results showed that in the process of WAAM, it is necessary to control the appropriate heat input to achieve minimum heat accumulation and improve the performance of the deposited parts. To obtain higher mechanical properties (tensile strength has been increased by 28%–45%), aluminum matrix composites by WAAM have proved to be an effective method. The corresponding proper heat treatment can also increase the tensile strength of WAAM Al alloy by 104.3%. In addition, mechanical properties are always assessed to evaluate the quality of deposited parts. The mechanical properties including the tensile strength, yield strength, and hardness of the deposited parts under different processing conditions have been summarized to provide a reference for the quality evaluation of the deposition. Examples of industrial products fabricated by WAAM are also introduced. Finally, the application status of WAAM aluminum alloy is summarized and the corresponding future research direction is prospected.