Arc Additive Manufacturing Research Articles

Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

Experimental study of shielding gas concentration on mechanical properties of stainless steel alloy parts using wire and arc additive manufacturing

Wire Arc Additive Manufacturing (WAAM) is an emerging three-dimensional fabrication technology that enables higher deposition rate, material savings, and near net-shape. In this study, various shielding gas concentration (SGC) of argon (Ar) and carbon-di-oxide (CO2) was employed to fabricate 316L using Cold Metal Transfer (CMT) WAAM process. Microstructure characteristics and mechanical properties of thick-walled parts were studied. Microstructure studies show a combination of columnar and equiaxed grains in various regions. Microhardness results exhibit the uneven distribution of hardness value from bottom to top region along the building direction and the values are ranging between185 and 240 HV. Tensile studies indicates the both horizontal and vertical direction samples secures the higher ultimate tensile strength (UTS), yield strength (YS) and elongation (EL) values and confirmed the isotropic properties. Fractography studies prove ductile fracture with the evidence of dimples and enough plastic deformation. From the experimental results, the SGC-2 possesses finer solidification structure and higher mechanical properties than the other samples. The as-fabricated WAAM parts possess higher mechanical properties than the 316L parts fabricated via casting and wrought parts.

Investigating the Impact of Robotic Milling Parameters on the Surface Roughness of Al-Alloy Fabricated by Wire Arc Additive Manufacturing

This paper takes the single-wall wall manufactured by wire arc additive manufacturing (WAAM) as the research object and compares it with the as-cast aluminum alloy with the same series. By using feed rate, cutting depth, spindle speed, etc., as single or compound parameters, the machinability of the sample is analyzed. The results indicate that the influence of varying parameters on the as-deposited aluminum alloy follows the order of feed rate > cutting depth > spindle speed. As the feed rate increases, the surface roughness initially decreases and then increases, with the optimal surface quality achieved at 12 mm/s (with a surface roughness of 2.013 μm). Different from the as-deposited alloy, the influence of the parameters on the as-cast alloys follows the order of spindle speed > cutting depth > feed rate. The experiments reveal that, for both as-deposited and as-cast states, the trends of the impact of cutting depth and spindle speed on surface quality are consistent. However, at low feed rates (2–12 mm/s), for as-deposited states, the surface quality of as-deposited samples becomes smoother as the feed rate increases (contrary to common knowledge). This result can be attributed to the elevated milling temperature, which softens the material, making it easier to remove and reducing the surface roughness.

Research on the differences of mechanical properties between horizontal and vertical in al-cu alloy deposits fabricated by wire + arc additive manufacturing

Research on the differences of mechanical properties between horizontal and vertical in al-cu alloy deposits fabricated by wire + arc additive manufacturing

Influence of Ageing Treatment on Microstructure and Mechanical Properties of GH4169 Alloy Prepared Using Wire Arc Additive Manufacturing

The effects of solid-solution and ageing treatments on the microstructure and mechanical properties of a GH4169 alloy made by wire arc additive manufacturing, micro-casting, and forging were researched. The microstructure, along with the size and type of precipitated phase, were analysed using an optical microscope, scanning electron microscope, and transmission electron microscope. The strength and toughness were tested using a tensile testing machine. The results show that a polygonal austenite microstructure was obtained for the GH4169 alloy prepared through wire arc additive manufacturing, micro-casting, and forging, followed by solid-solution and double-ageing treatments at different times. There were a few twins in the austenite matrix. A large number of nano-sized γ″- and γ′-precipitated phases and a small number of Laves phases and MX phases were found in the matrix. The tensile strength and yield strength of the GH4169 alloy increased first and then decreased with the ageing time. After ageing for 16 h, the maximum yield strength was 1287 ± 22 MPa, the maximum tensile strength was 1447 ± 19 MPa, and the elongation was about 19.5%. The main strength mechanism is precipitated phase strength and solid-solution strength. The fracture exhibited obvious ductile fracture characteristics.

Numerical investigation of arc characteristics and metal properties in ELAMF-assisted WAAM with wire retraction

In this study, a multi-physics integrated model of wire arc additive manufacturing (WAAM) with wire retraction and external longitudinal alternating magnetic field (ELAMF) assistance is proposed and validated, and the effect of ELAMF on the arc plasma characteristics and metal properties are systematically and quantitatively investigated. The model comprehensively takes the arc plasma heating, wire dynamic retraction, droplet transfer, the formation and diffusion of metal vapor, the melting and solidification of molten metal, and the stirring effect of ELAMF into account. The simulated results show that ELAMF has compressed the arc morphology, and decreased the temperature, potential, current density and static pressure, which are most pronounced when the wire is at an elevated position and the transient current is at its peak phase. Meanwhile, the formation of low-temperature and low-velocity cavities in the center of arc column are promoted by ELAMF, consequently diminishing the energy transferred from the arc plasma to molten pool through thermal conduction and mitigating the squeezing of the arc plasma on the surface of molten pool. The results also demonstrate that the ELAMF has reduced the temperature gradient of liquid metal inside the molten pool, and intensified the forced convection for the occurrence of multiple circulations.

Investigation of Fabricating Stainless Steel 304L Thin-Wall Structure Using Laser Marking-Assisted Wire Arc Additive Manufacturing Process

Investigation of Fabricating Stainless Steel 304L Thin-Wall Structure Using Laser Marking-Assisted Wire Arc Additive Manufacturing Process

Insights into Functionally Graded Materials Fabricated by Wire Arc Additive Manufacturing: A Comprehensive Review

Insights into Functionally Graded Materials Fabricated by Wire Arc Additive Manufacturing: A Comprehensive Review

Analysis of Microstructure and Mechanical Properties of Inconel 625 Alloy by Wire Arc Additive Manufacturing (WAAM)

Analysis of Microstructure and Mechanical Properties of Inconel 625 Alloy by Wire Arc Additive Manufacturing (WAAM)

Monitoring the gas metal arc additive manufacturing process using unsupervised machine learning

The study aimed to assess the performance of several unsupervised machine learning (ML) techniques in online anomaly (The term “anomaly” is used here to indicate a departure from expected process behavior which may indicate a quality issue which requires further investigation. The term “defect detection” has often been used previously but the specific imperfection is often indirectly inferred.) detection during surface tension transfer (STT)-based wire arc additive manufacturing. Recent advancements in quality monitoring for wire arc manufacturing were reviewed, followed by a comparison of unsupervised ML techniques using welding current and welding voltage data collected during a defect-free deposition process. Both time domain and frequency domain feature extraction techniques were applied and compared. Three analysis methodologies were adopted: ML algorithms such as isolation forest, local outlier factor, and one-class support vector machine. The results highlight that incorporating frequency analysis, such as fast Fourier transform (FFT) and discrete wavelet transform (DWT), for feature extraction based on general frequency response and defined bandwidth frequency response, significantly improves performance, reflected in a 14% increase in F2 score, compared with time-domain features extraction. Additionally, a deep learning approach employing a convolutional autoencoder (CAE) demonstrated superior performance by processing time-frequency domain data stored as spectrograms obtained through short-time Fourier transform (STFT) analysis. The CAE method outperformed frequency domain analysis and traditional ML approaches, achieving an additional 5% improvement in F2-score. Notably, the F2-score (The F2 score is the weighted harmonic mean of the precision and recall (given a threshold value). Unlike the F1 score, which gives equal weight to precision and recall, the F2 score gives more weight to recall than to precision.) increased significantly from 0.78 in time domain analysis to 0.895 in time-frequency analysis. The study emphasizes the potential of utilizing low-cost sensors to develop anomaly detection modules with enhanced accuracy. These findings underscore the importance of incorporating advanced data processing techniques in wire arc additive manufacturing for improved quality control and process optimization.

Study of mechanical and metallurgical properties of wire arc additively manufactured inconel 718 alloy

The current research work deals with the investigation of mechanical, wetting transition on grain boundary (GB) and metallurgical properties of Inconel 718 alloy used in aerospace industrial applications. The fabrication of thin-wall structure (multilayer structure) is fabricated using wire arc additive manufacturing (WAAM) technique. The novelty of this method is that gas metal arc welding (GMAW) is used as energy source and cold metal transfer (CMT) is used as mode of droplet transfer. Four tensile samples are extracted asper ASTM E8/E8M standards and three microstructure samples are extracted from thin wall structure. Optical microscopy (OM), SEM, EDAX, and EBSD analysis were carried out. In addition, Hardness and tensile tests, as well as fractography analysis were conducted. The grain boundary wetting transition (GBWT) analysis is also carried out. SEM analysis reveals that Nb-rich MC-type carbide contains grain boundaries of droplets, indicating incomplete wetting. Laves and delta (δ) phases are also identified as liquids of a continuous layer separated by Ni elements, indicating complete wetting. EBSD analysis indicates the average grain size as 251.2 μm. The average value of micro hardness as 417.3 HV and UTS as 609.75 MPa are achieved.

Space–time topology optimization for anisotropic materials in wire and arc additive manufacturing

Wire and Arc Additive Manufacturing (WAAM) has great potential for efficiently producing large metallic components. However, like other additive manufacturing techniques, materials processed by WAAM exhibit anisotropic properties. Assuming isotropic material properties in design optimization thus leads to less efficient material utilization. Instead of viewing WAAM-induced material anisotropy as a limitation, we consider it an opportunity to improve structural performance. This requires the integration of process planning into structural design. In this paper, we propose a novel method to utilize material anisotropy to enhance the performance of structures both during fabrication and in their use. Our approach is based on space–time topology optimization, which simultaneously optimizes the structural layout and the fabrication sequence. To model material anisotropy in space–time topology optimization, we derive the material deposition direction from the gradient of the pseudo-time field, which encodes the fabrication sequence. Numerical results demonstrate that leveraging material anisotropy effectively improves the performance of intermediate structures during fabrication as well as the overall structure.

Dissimilar joining of Ti–6Al–4V to 316L stainless steel by a novel joining process based on arc additive manufacturing and combined twin-wire arc welding

The joining structure of Ti–6Al–4V to 316L stainless steel has potential demands in many fields. However, it is very difficult to avoid the formaiton of intermetallic compounds (IMCs) of the weld between Ti–6Al–4V to 316L stainless steel, which will severely decrease joint properties. In this paper, a novel joining technology that combines the single wire backing arc welding and the spatially arranged combined twin-wire arc welding was utilized to join Ti–6Al–4V and 316L stainless steel. Copper alloy wire (S214) and vanadium alloy wire (V01) were used as filler metals to produce two isolation layers, which prevented the formation of IMCs. The phase compositions at the Fe/Cu, Cu/V and V/Ti interfaces were Fe(S,S) + Cu(S,S), Cu(S,S) + V(S,S) and V(S,S)+(β-Ti, V)SS respectively. The distribution of the spherical and clustered V(S,S) particles in the matrix at the Cu/V interface contributes to dispersion strengthening and solid solution strengthening of the interface. Tensile strength of 394 MPa with an elongation of 2.53% was achieved. The joint fractured at the Cu/V interface of the single wire backing arc weld and the Cu zone of the spatially arranged combined twin-wire arc weld respectively. Dimple plastic fracture modes were detected in the joints. This technology is not only applicable to Ti–6Al–4V titanium alloy/316L stainless steel dissimilar metal joining, but also provides a new research strategy for the joining between other dissimilar metals.

Evaluation of mechanical and microstructural characteristics in different regions of wire arc additive manufactured 304L austenitic stainless steel

ABSTRACT The large structural components (304 L austenitic stainless steel) used in nuclear power plants are difficult and expensive to manufacture and machine using standard methods. Wire arc additive manufacturing (WAAM) is a low cost and high deposition method for fabricating large structural parts. Therefore, in this investigation, 304 L austenitic stainless steel (304 L ASS) cylindrical component was fabricated using WAAM technique. The mechanical and microstructural characteristics of the bottom (region ①) and top (region ②) of the WAAM 304 L ASS component are studied. The microstructure of region ① consists of austenite and ferrite with vermicular and lathy morphologies, while region ② consists of skeletal and reticular morphologies. In regions ① and ②, yield strength (YS), ultimate tensile strength (UTS), and elongation (EL) were found to be 350 ± 7 MPa, 562 ± 10 MPa, and 75 ± 1%, respectively. The impact toughness and hardness in regions ① and ② were found to be 112 ± 2 J and 183 ± 6 (Hv0.5), respectively. From the results, it is evident that the tensile properties of the WAAM 304 L ASS component were equal/greater than the values of the forged 304 L ASS material, wrought 304 L ASS alloy, and 304 L ASS filler wire.

Prediction and optimization of surface waviness of WAAM components using a hybrid Rank-Gaussian PSO algorithm and ANN

Surface waviness is crucial for the quality of components produced via the wire and arc additive manufacturing (WAAM) process. This study presents a novel method for predicting surface waviness, employing an advanced model to optimize process parameter configurations using a combination of Rank-Gaussian particle swarm optimization (RGPSO) and an Artificial Neural Network (ANN). The novelty of this process is that the RGPSO not only optimizes the hyperparameters of the ANN model to enhance prediction performance, but also addresses surface waviness optimization. The RGPSO algorithm's optimization performance is evaluated using 23 benchmark functions, demonstrating competitiveness against nine comparative meta-heuristic algorithms. Experimental data on surface waviness from the literature are utilized to train, test and validate three different prediction models, including a standalone ANN model, a PSO optimized ANN (PSO-ANN) model, and an RGPSO optimized ANN (RGPSO-ANN) model. The results indicate that the developed RGPSO-ANN model achieves the highest accuracy in terms of the metrics RMSE (0.019), R (0.996), R20.990,MAE (0.013), RMSLE0.013,and MAPE (3.46 %). It performs better than the PSO-ANN model (RMSE 0.026, R 0.975, R20.982,MAE 0.019, RMSLE0.019,and MAPE 5.73 %), and better than the ANN (RMSE 0.046, R0.991, R20.944,MAE 0.034, RMSLE0.032 and MAPE 9.31 %). The RGPSO, PSO and other optimization algorithms are then applied to minimize the surface waviness of a WAAM component. RGPSO achieved the optimal value (0.1631 mm), which corresponds to a 12.6 % reduction compared to the best value obtained using PSO.

Research on the microstructure and mechanical properties of functional gradient materials of TC4/TC11 titanium alloys for wire arc additive manufacturing with different transitional forms

Functional gradient materials (FGMs) have garnered increasing interest for their potential in material and structural design. Additive manufacturing, as a kind of free manufacturing and near-net shaping technology with in-situ controllability of materials, is the dominant technology for fabricating FGMs. While numerous studies have been conducted on titanium alloy FGMs, there is still a lack of research on the structure and properties of the material with the number of transitional layers. This study employs double-wire arc additive manufacturing to fabricate FGMs composed of TC4 and TC11 alloys. The study examines the utilization of direct and continuous transition forms in conjunction with stress relieving and solution aging heat treatment processes. The composition, grain morphology, microstructure, and mechanical properties of FGMs are analyzed. Results indicate that in samples employing direct transition, higher heat treatment temperatures and durations lead to a more uniform composition and microstructure. Additionally, the interface morphology becomes increasingly indistinct, and transversal elongation at the interface is enhanced by the strain compensation of the two materials. In continuous transitional samples, an increase in the number of transitional layers results in a more uniform microstructure near the interface, leading to a reduction in interface morphology and an enhancement of mechanical properties. The fracture position tends to shift closer to the TC4 side, with both process forms exhibiting ductile fractures. The plasticity of the TC4 part is superior, and the ductile fracture morphology is more pronounced. This study offers a valuable experimental foundation for investigating the direct and continuous transition of titanium alloy FGMs.

Effect of nitrogen content on microstructure and mechanical properties of duplex stainless steels via wire arc additive manufacturing

Effect of nitrogen content on microstructure and mechanical properties of duplex stainless steels via wire arc additive manufacturing

Additive manufacturing by the selective paste intrusion: Effect of the distance of the print nozzle to the particle bed on the print quality

Selective Paste Intrusion (SPI) is an additive manufacturing (AM) process in which thin layers of aggregates are selectively bonded by cement paste only where the structure is to be produced. In this way, concrete elements with complex geometries and structures can be created. Reinforcement is required to increase the flexural strength of the concrete elements and, thus, enable their applicability in practice. Integrating the reinforcement is a difficult task, particularly in the case of SPI, due to the layerwise printing method. Especially with respect to possible complex structures, the production of the reinforcement needs to be adapted to SPI, thereby offering a high degree of freedom. One concept for reinforcement integration is combining the two additive manufacturing processes, SPI and Wire and Arc Additive Manufacturing (WAAM). However, since the two processes serve different fields of application, their compatibility is not necessarily given. Ongoing investigations show that the temperatures caused by WAAM adversely affect both the cement paste rheology required for sufficient paste penetration into the particle bed and the overall concrete strength. This paper provides an overview of ongoing research focusing on different cooling strategies and their effects on the compressive strength of SPI-printed concrete parts.

Effect of interlayer ultrasonic impact on the microstructure, mechanical and corrosion properties of wire arc additive manufacturing AZ31 Mg alloy thin wall

AZ31 Mg alloy thin walls are prepared using wire arc additive manufacturing (WAAM) and interlayer ultrasonic impact (UI) techniques with cold metal transition (CMT) serving as the heat source. The microstructure, mechanical and corrosion properties of thin walls prepared by WAAM and WAAM + UI are studied. Results showed that the recrystallization area fraction along traveling direction (TD) increased by 68.6% after UI treatment, and many fine equiaxed crystals were formed, resulting in grain refinement, anisotropy reduction, mechanical and corrosion properties improvement. The average grain size along TD decreased from 66.6 ± 3.5 μm to 32.7 ± 1.6 μm. Through UI treatment, the ultimate tensile strength (UTS) and elongation (EL) along TD increased from 205 MPa to 230 MPa and 13.5%–17%, respectively. The anisotropic percentage of UTS and EL were decreased from 10.8% to 4.5%, and 42.1%–9.7%, respectively. Electrochemical experimental results showed that the average corrosion rate along TD decreased from 1.93 mm year−1 to 1.53 mm year−1. Grain refinement, dislocation density variation and texture strength reduction were the main reasons for these results.

Effect of Different Welding Modes on Morphology and Property of SS316L Stainless Steel Deposition by Robotic Metal-Inert Gas Welding.

The widespread adoption of arc additive manufacturing techniques across various industries has advanced the field of SS316L stainless steel manufacturing. It is crucial to acknowledge that different welding modes exert distinct influences on the forming and mechanical performance. This study analyzed the thermal input associated with four specific welding modes in LORCH MIG welding, clarifying the transition dynamics of molten droplets through waveform analysis and examining the resultant effects on microstructure and performance characteristics. The Pulse, Speed-Pulse-XT, and Twin-Pulse modes were found to induce spatter during the manufacturing process, consequently reducing molding efficiency in comparison to the SA-XT mode. Notably, the Twin-Pulse mode, characterized by double-pulse agitation, generated fish scale patterns along the lateral surfaces of the fabricated parts, promoting anisotropic grain growth. This microstructural refinement, compared to single-pulse samples with equivalent thermal input, resulted in enhanced mechanical properties. Nevertheless, the horizontal tensile strength of the three pulse modes was lower than the industrial standard for SA-XT mode and forging. In contrast, the SA-XT mode with an average hardness of 168.1 ± 6.9 HV and a tensile strength of 443.58 ± 5.7 MPa. Therefore, while three pulse modes offer certain microstructural advantages, the SA-XT mode demonstrates superior overall performance.