Wire Arc Additive Manufactured Research Articles

Microstructural characteristics and properties of wire arc additive manufactured 304L austenitic stainless steel cylindrical components by different arc welding processes

Wire arc additive manufacturing (WAAM) is an advanced additive manufacturing (AM) technology that offers low cost and high deposition rates, making it suitable for building large metal parts for structural engineering applications. However, various welding procedures result in differing heat inputs and repetitive heating treatments throughout the deposition process, which can affect the microstructural and mechanical characteristics of the parts. In the current study, cylindrical parts made of 304L austenitic stainless steel (ASS) were manufactured using the WAAM technique, employing both gas metal arc welding (GMAW) and cold metal transfer (CMT) processes. This study explores the correlation between WAAM techniques and their effects on the bead geometry, microstructure and mechanical properties. The microstructure of the cylinders consisted of vertically growing austenite dendrites with residual ferrite (δ) within the austenite (γ) matrix. Compared to the bottom region (region ①), the top region (region ②) contained more residual ferrite. Although the microstructural characteristics from region ① to region ② are similar, they exhibit different ferrite morphologies. The rapid cooling rate in the CMT-AM process resulted in finer structures and a greater presence of ferrite phases in both regions compared to the GMAW-AM method. Cylinders produced by the CMT process displayed nearly uniform properties across both regions and demonstrated superior tensile properties, hardness, and impact toughness relative to those made using the GMAW technique. The WAAM 304L ASS cylinders also showed enhanced performance compared to stainless steel manufactured using traditional industrial forging standards, indicating that WAAM-processed 304L ASS cylinders are suitable for industrial applications.

Effect of gas protection on form and microstructure of wire arc additive manufactured WE43 magnesium alloy

In this study, WE43 magnesium alloy was successfully fabricated using wire arc additive manufacturing technology, focusing on reducing the common oxide inclusion defects. The implementation of a gas shielding hood significantly improved the grain morphology of the deposited samples and diminished both the quantity and size of oxides. In addition, the cooling effect induced by the shielding gas contributed to the refinement of grain size. The synergistic effect of oxide reduction and grain refinement significantly improves the mechanical properties of the deposited samples. For heat treatable magnesium alloys, minimizing the consumption of rare earth elements is beneficial for optimizing heat treatment mechanical properties.

Dimension Prediction and Microstructure Study of Wire Arc Additive Manufactured 316L Stainless Steel Based on Artificial Neural Network and Finite Element Simulation.

The dimensional accuracy and microstructure affect the service performance of parts fabricated by wire arc additive manufacturing (WAAM). Regulating the geometry and microstructure of such parts presents a challenge. The coupling method of an artificial neural network and finite element (FE) is proposed in this research for this purpose. Back-propagating neural networks (BPNN) based on optimization algorithms were established to predict the bead width (BW) and height (BH) of the deposited layers. Then, the bead geometry was modeled based on the predicted dimension, and 3D FE heat transfer simulation was performed to investigate the evolution of temperature and microstructure. The results showed that the errors in BW and BH were less than 6%, and the beetle antenna search BPNN model had the highest prediction accuracy compared to the other models. The simulated melt pool error was less than 5% with the experimental results. The decrease in the ratio of the temperature gradient and solidification rate induced the transition of solidified grains from cellular crystals to columnar dendrites and then to equiaxed dendrites. Accelerating the cooling rate increased the primary dendrite arm spacing and δ-ferrite content. These results indicate that the coupling model provides a pathway for regulating the dimensions and microstructures of manufactured parts.

Enhanced high-temperature strength and ductility of wire arc additive manufactured Al–Ce–Mg alloys with fine α-Al/Al11Ce3 eutectics

Here, wire-arc additive manufacturing (WAAM) is employed to fabricate Al–Ce–Mg heat-resistant aluminum alloy, considering its capability to manufacture large complex structures more efficiently. Large-sized faceted Al11Ce3 intermetallic compounds are formed in the as-cast alloy with a hypereutectic microstructure. The microstructure is transformed to a eutectic microstructure by non-equilibrium solidification of WAAM, consisting lamellar α-Al/A111Ce3 eutectics. The WAAM alloy shows enhanced mechanical strength and ductility at 200 °C, compared with the as-cast alloy. The significant improvements of ultimate tensile strength and elongation for the WAAM alloy are correlated with its higher strain hardening rate, along with the transition from cleavage fracture to dimple fracture. The cracking of All1Ce3 particles occurs preferentially during the elastic deformation stage, as revealed by in-situ testing, and the strain hardening capability of the as-cast alloy is reduced. Pore defects, 0.15 % in volume fraction, are produced via WAAM processing, and the plastic deformation promotes the pore growth and mergence, increases the pore volume fraction, and decreases the pore sphericity. Our results demonstrate that WAAM is strongly attractive for the fabrication of Al–Ce–Mg alloys, due to the enhanced high-temperature strength-ductility synergy.

Bead Geometry Control in Wire Arc Additive Manufactured Profile — A Review

Wire arc additive manufacturing (WAAM) is a well-established additive manufacturing method that produces 3D profiles. A better deposition efficiency can be achieved by understanding the parameters that may influence the geometry of the bead. This paper provides a review that focuses on the factors that may influence the formation of the 3D profile. The included factors are the flow pattern of the molten pool after deposition, the built structure and orientation, the heat input and cooling conditions, the welding parameters, and other uncertainties. This review aims to facilitate a better understanding of these factors and achieve the optimum geometry of the 3D parts produced. According to the literature, the behavior of molten pools is identified as one of the major factors that can impact the deposition efficiency of a bead and govern its geometry. The review indicated that the flow behavior of the molten pool and the geometry of the deposited bead are significantly affected by most welding parameters, such as torch angle, wire travel speed, filler feed rate, and cooling conditions. Furthermore, this paper incorporates the technology utilized for comprehending the behaviors of the molten pool, as it constitutes an integral component of the control strategy. It has been concluded that automated planning and strategy are necessary to ensure efficient deposition by controlling those factors. The integration of artificial intelligence could bring benefits in planning to address the variation and complexity of shapes.

Integrated approach to Wire Arc Additive Manufacturing (WAAM) optimization: Harnessing the synergy of process parameters and deposition strategies

The flexibility of Additive Manufacturing (AM) technologies in the metal 3D printing process has gained significant attention in research and industry, which allows for fabricating complicated and intricate Near-Net-Shape (NNS) geometry designs. The achievement of desired characteristics in Wire-Arc Additive Manufactured (WAAM) components is primarily contingent upon the careful selection and precise control of significant processing variables, including bead deposition strategy, wire materials, type of heat source, wire feed speed, and the application of shielding gas. As a result, optimizing these most significant process parameters has improved, producing higher-quality WAAM-manufactured components. Consequently, this has contributed to the overall rise in the method's popularity and many applications. This article aims to provide an overview of the wire deposition strategy and the optimization of process parameters in WAAM. The optimization of numerous wire deposition techniques and process parameters in the WAAM method, which is required to manufacture high-quality additively manufactured metal parts, is summarised. The WAAM optimization algorithm, in addition to anticipate technological developments, has been proposed. Subsequently, a discussion ensues regarding the potential for WAAM optimization within the swiftly growing domain of WAAM. In the end, conclusions have been derived from the reviewed research work.

Microstructure, mechanical properties, and corrosion behaviour of wire arc additive manufactured martensitic stainless steel 410 for pressure vessel applications

High-strength martensitic stainless steel 410 (MSS 410) was successfully fabricated without defects via wire arc additive manufacturing (WAAM). The microstructural features, mechanical properties, and corrosion performance of WAAM-processed MSS 410 were examined. Microstructural analysis revealed the existence of equiaxed and coarse columnar dendrites and the formation of residual delta-ferrite and retained-austenite (RA) was confirmed within the martensitic matrix. The fraction of residual ferrite and RA varied along the building direction due to complex thermal cycles. Uni-axial tensile results exhibited anisotropic behavior and are related to layered microstructure. Microhardness values varied from bottom to top (384–460 HV). Ductile mode of failure was noticed, and the existence of RA influences the ductility. The corrosion behaviour of the WAAM 410 specimens in 3.5% NaCl solution was considerably acceptable, and the corrosion rate ranged between 0.05 and 1.37 mpy. This shall be attributed to the absence of defects, microstructural features, and ferrite fraction in the WAAM 410 samples. The mechanical properties and corrosion behaviour of the WAAM 410 were comparable to the wrought grade and are suitable for pressure vessel applications with adequate corrosion resistance.

Multiaxial low cycle fatigue behavior and life prediction of wire arc additive manufactured 308L stainless steel

Wire arc additive manufacturing (WAAM) is a technique that has gained popularity in various industrial sectors due to its high productivity and flexibility. However, the comprehension of cyclic deformation and fatigue behaviors in WAAM austenitic stainless steel (SS), particularly under complex multiaxial loading conditions, is much less advanced compared to conventional manufacturing methods. This study aims to fill some of these gaps by performing fatigue tests of WAAM 308L SS under axial, torsional and axial–torsional multiaxial loadings. Similar tests were carried out on the hot-rolled 308L SS as a basis for comparison. WAAM 308L SS exhibits notable distinctions in cyclic deformation, fatigue life, cracking mode and fatigue failure mechanisms compared to its hot-rolled counterparts as a result of its distinct manufacturing technologies and resulting microstructures. To assess all fatigue life data, three critical plane criteria, namely FS, SWT and CXH criteria, were employed. The CXH model, which considers the effects of both tensile and shear damage on fatigue properties, has the ability to predict the fatigue life of both hot-rolled and WAAM 308L SS.

Effect of Layer Addition on Residual Stresses of Wire Arc Additive Manufactured Stainless Steel Specimens

Abstract Residual stresses have been characterized in four Wire Arc Additive Manufacturing specimens with neutron diffraction technique. First, two methods are investigated for obtaining the reference diffracted angle θ0 that is required for the computation of microstrains and, thus, the stresses; θ0 was obtained with two approaches. The first one required a strain-free specimen in order to get directly the reference diffracted angles θ0 in the three principal directions. The second one is based on the plane stress assumption to get θ0 indirectly by imposing that the normal stress was equal to zero. Both methods led to similar residual stress profiles for the one-layer specimen which validated this approach for all specimens without a strain-free specimen available. The second part of this work focused on the modification of the residual stresses in the specimen following the addition of a new deposit. The neutron diffraction measurements showed that the longitudinal stress was tensile in the heat-affected and fusion zones with a maximum value located at the parent material–layers interface where the thermal loadings were applied. A decrease of this maximum value from 257 MPa to 199 MPa appeared after deposition of a new layer which is due to some stress relaxation effect. Inside the parent material, a large zone presents compressive longitudinal stress up to −170 MPa. The bottom part of the parent material is under tensile stress likely due to its upward bending following the thermal contraction of the deposited layers during cooling to ambient temperature.

Effect of interpass temperature on austenite ferrite ratio of wire arc additive manufactured 2507 Super Duplex Stainless Steel

In this research work, a thin wall structure has been developed using 2507-grade Super Duplex Stainless Steel (SDSS) using Wire-Arc Additive Manufacturing (WAAM) with varied interpass temperatures to determine the effect of interpass temperature on the austenite-ferrite ratio of the SDSS WAAM structure. Studies such as X-ray diffraction and Electron back-scattered diffraction analysis reveal a balanced (38.1–61.9%) austenite-ferrite in the 150 ˚C interpass temperature, resulting in higher hardness and strength.

TIG assisted surface finish enhancement in MIG-based wire arc additive manufacturing

TIG arc treatment was explored to enhance the surface finish of wire arc additive manufactured (WAAM) parts, addressing issues of waviness and roughness. It offers precise control over input parameters providing an economical solution for selective thermal surface treatment. This study investigates the influence of peak current on surface finish and associated impact on hardness. A hybrid MIG-TIG process was employed which minimised the waviness efficiently, however resulted in low hardness, requiring further treatment to restore hardness. This approach reduced surface roughness by ∼ 40 %, offering efficient and cost-effective selective treatment, with the potential to improve surface quality and mechanical properties.

Feasibility study of wire arc additive manufactured P91 steel by cold metal transfer deposition

The objective of this study was to analyze and evaluate the feasibility of utilizing Wire Arc Additive Manufacturing (WAAM) technology for the constructing components made from P91 steel, which is widely used material for high-temperature applications. The utilization of the Cold Metal Transfer (CMT) method enables the deposition of thin steel walls by virtue of its low heat input. Samples collected from the deposited wall have been tested in two different microstructural conditions, in the as-built (AB) condition and in a normalized and tempered (NT) condition. The latter condition is the microstructural state commonly employed for producing components used in power plants. This post-deposition heat treatments (PDHT) comprise a normalization process conducted at 1050 °C for 40 min, followed by a tempering step at 760 °C for 2 h. The results of mechanical testing and microstructural characterization were then compared against the established standards for commercial P91 steel. SEM-EDAX, XRD, and EBSD analyses were employed to conduct a comprehensive microstructural examination of the samples. The hardness of the AB samples ranged from 384 to 439 HV, while the NT samples had a hardness range of 205 to 223 HV. In terms of tensile strength, the AB samples demonstrated a range of 1064 to 1266 MPa, whereas the NT samples exhibited a range of 635 to 626 MPa. These results were found to be consistent with the observed strong texture and grain orientations in the {001} and {111} planes, as revealed by the EBSD analysis. The NT components demonstrated significant strength, ductility, hardness, and toughness compared to the specified ASTM standards. Based on the test performance and feasibility criteria, this process has significant potential as an additive manufacturing method suitable for complex boiler components.

Infrared imaging surface roughness criticality assessment of Wire Arc Additive Manufactured specimens

Infrared imaging surface roughness criticality assessment of Wire Arc Additive Manufactured specimens

Fatigue and anisotropic behavior of wire-arc additive manufactured TC17 titanium alloy

Wire-arc additive manufacturing (WAAM) was used in aeronautical engineering due to its low equipment cost and ability to create complex shapes. However, the fatigue behavior of WAAM titanium alloy, specifically for low cycle fatigue (LCF), was poorly studied. This paper investigated the microstructure and mechanical behavior of WAAM TC17 in both vertical and horizontal orientations. Fully reversed LCF tests were conducted on specimens with varying strain amplitudes from ±0.4 % to ±1.2 %. The results found that the ultimate tensile and yield strength were similar for both vertical and horizontal samples, but the elongation in the horizontal orientation was approximately 60 % lower than that in the vertical orientation. Considering the cyclic loading behavior, both vertical and horizontal samples exhibited cyclic softening characteristics at high strain amplitudes (0.8%–1.2 %). Additionally, the cyclic softening rate (CSR) of horizontal samples exhibited a higher than that of vertical samples at high strain amplitude. The LCF cracks of WAAM TC17 were initiated from the surface and internal defects of the samples. The LCF performance of the horizontal samples was found to decrease than that of vertical samples. Specifically, the fatigue performance of the horizontal samples is lower by 36.7 % compared to the vertical samples when the number of cycles is 103.

Experimental investigations on the microstructural evolution and their influence on mechanical, tribological and corrosion performance of wire-arc additive manufactured SS316L structure

The study investigates the feasibility of emerging wire arc additive manufacturing technology to fabricate steel structures. The grain morphology and phase transformation of the WAAM-printed structure have been thoroughly examined and investigated their influence on the mechanical, tribological, and corrosion performance. The structure is characterized by fine equiaxed grains nearer to the cold substrate and coarse columnar grains along the upper regions. The average grain size in the top, middle, and bottom regions of the printed wall is 12.34 ± 5.81 µm, 10.27 ± 2.84 µm, and 4.33 ± 0.89 µm respectively. The higher temperature gradient in the bottom regions led to the ferrite-austenite solidification mode that switched toward the primary austenite solidification mode in the upper layers. The printed parts witness superior mechanical properties with an improved micro-hardness and tensile strength however reduced ductility compared to the conventionally produced steel. The longitudinal direction of the printed parts experienced slightly higher hardness than the transverse. The tribological performance in different regions is investigated under different loading conditions and discovered an improvement in the wear-resistant properties of the fabricated part to its wrought counterpart even at high load conditions. Moreover, comparative corrosion resistance properties of the WAAM and wrought steel were detected with a slightly higher corrosion rate along the upper region in a moderately saline environment with flowing and stagnant conditions. The study detects the dependence of the characteristics properties on the grain morphology and existing phases in different regions of the arc additive-manufactured steel wall.

Investigation of residual stresses and modeling of tensile deformation in wire-arc additive manufactured 6061 aluminum alloy: Diffraction and elastoplastic self-consistent model

The aim of this work is to study the mechanical behavior of 6061 aluminum walls produced by Wire Arc Additive Manufacturing at the different scales of the material. The residual stresses of the parts are characterized on the surface and in the bulk thanks to X-ray and neutron diffraction techniques, respectively. Although the residual stress values determined in the close-surface are low (40 MPa for the maximum value), the mechanical state is different in depth with significant maximum residual stress levels ( ± 100 MPa). Tensile tests carried out on samples extracted from a WAAM wall in three orientations reveal that the mechanical properties of the manufactured material are slightly better compared to conventional material in T6 state. In situ X-ray diffraction experiments have also been performed under uniaxial tensile testing in order to determine strain pole figures. An elasto-plastic self-consistent model considering the microstructural characteristics and the main physical phenomena governing the material behavior, is proposed. The model agrees with the experimental data and the simulations reproduce the main features observed at the scale of the diffracting volume.

Investigation of mechanical and microstructure properties of metal inert gas based wire arc additive manufactured Inconel 600 superalloy

Abstract This work aims to fabricate the functionally graded Inconel 600 on stainless steel 304 block using the wire arc additive manufacturing process. The main goal of this study was to additively create a built block with Inconel 600 filler wire. Inconel 600 is a very interesting material because of its resistance to non-magnetic, corrosive media, stress corrosion cracking due to chlorine ions is non-existent, outstanding mechanical properties, good weldability and high strength under a variety of temperature conditions. Inconel 600 alloy was studied in this work utilizing metal inert gas based wire arc additive manufacturing. Torch travel speed 5 mm s−1 and current 140 A. The bottom, middle and top layers of the newly developed fabricated block were mechanically and metallurgically characterized. The microstructure and texture evolution were characterized by means of optical microscopy, and scanning electron microscopy with energy dispersive X-ray spectroscopy. Mechanical characterization was done using the Vickers hardness test and tensile testing. Results reveal that the wire arc additively manufactured top portion has a crystalline structure showing better strength and hardness. The average hardness value was found to be 197.97 HV, the average ultimate tensile strength obtained was 616.22 MPa for the fabricated component.

Wire arc additive manufactured AWS ER100S-G steel: Very high cycle fatigue characterization

This paper presents a comprehensive study on the very high cycle fatigue (VHCF) characterization of a wire arc additive manufactured (WAAM) AWS ER100S-G steel. The demand for high-performance materials with superior fatigue properties has grown exponentially. However, the VHCF behavior of large-format WAAM’d structures remains relatively unexplored. In this study, a series of VHCF tests were conducted under fully reversed cyclic loading conditions to investigate the extended fatigue life (performance) of the WAAM ER100S-G steel. The VHCF properties, relative to conventional fatigue employing a servohydraulic testing system, of the WAAM ER100S-G steel were evaluated by analyzing the stress-life (S-N) curves, fatigue crack initiation, and propagation behavior, in a statistical framework, and the fracture surfaces. The results revealed the controlling mechanisms of VHCF failure of the WAAM ER100S-G steel and the fatigue response of the material beyond the conventional fatigue limit of 107 cycles. The findings provide valuable insights into the influence of WAAM-induced defects/microstructure on the extended fatigue performance of WAAM ER100S-G steel, which can aid in optimizing fatigue and durability design guidelines for additive manufacturing applications in high-cycle and very high-cycle fatigue domains.

Mechanical behaviour, microstructure and texture studies of wire arc additive manufactured 304L stainless steel

Abstract Wire arc melting is considered one of the most efficient processes in additive manufacturing in terms of material printed to material consumed ratio. 304 stainless steel is one of the prominent stainless steels with superior corrosion resistance and mechanical properties. 304 stainless steel components were deposited by wire arc additive manufacturing, depositing subsequent layers in the same and perpendicular directions. Mechanical properties, microstructure, XRD and microtexture studies were done by EBSD have been done for both the conditions and compared. Mechanical properties were found to be similar for both the conditions whereas the microstructure and microtexture showed equiaxed grains for depositing in the same direction and columnar grains for deposition in the perpendicular direction.

Effect of process modes on microstructure and mechanical properties of CMT wire arc additive manufactured WE43 magnesium alloy

The traditional WE43 magnesium alloy (WE43-Mg) manufacturing process faces challenges in producing large and complex structures. The cold metal transfer wire arc additive manufacturing (CMT-WAAM) offers a promising solution due to its flexibility, high deposition efficiency and low heat put. However, energy transfer and mass transfer are highly coupled in the CMT additive manufacturing process. Under different working modes, the local thermal processes are quite different for the same transition metals, which can produce different microstructures and mechanical properties. Therefore, it is necessary to study the effect of working modes on microstructure and mechanical properties. This study successfully deposited single-pass multi-layer WE43-Mg components using four CMT processes: CMT, CMT-Pulse, CMT-Advance, and CMT-Pulse + Advance. The microstructure and mechanical properties of these deposited samples were compared. Results revealed equiaxed grains with uniform sizes in the top and middle regions, with fine-grain regions between layers in the four CMT modes. Compare the microstructure characterization results, the higher the line energy, the narrower the width of the remelted fine grain zone. Four CMT modes deposited components exhibited superior mechanical properties compared to as-cast WE43-Mg. The CMT pulse mode shows the best results due to its low porosity. The average yield strength is 149.0 MPa, tensile strength is 222.9 MPa, and elongation is 6.4 %.