Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum

The symmetrical nature in the case of wall fabrication by wire arc additive manufacturing (WAAM) has been observed in the literature, but it has not been studied as a source of knowledge. This paper focuses on the comparative study of three drop transfer methods employing Gas Metal Arc Welding (GMAW) technology, one of the most reported for the manufacture of aluminum alloys. The transfer modes studied are the well-known pulsed GMAW, cold arc, and the newer pulsed AC. The novelty of the last transfer mode is the reversal of the polarity during the preparation phase of the substance for droplet deposition. This study compares the symmetry of zero beads to determine the best parameters and transfer modes for wire arc additive manufacturing of 5 series aluminum. The pulsed transfer modes show values of 0.6 for symmetry ratio, which makes them more interesting strategies than cold arc with a symmetry ratio of 0.5. Furthermore, the methodology proposed in this study can be extrapolated to other materials manufactured with this technology.

[1]  Xunpeng Qin,et al.  Understanding and overcoming of abnormity at start and end of the weld bead in additive manufacturing with GMAW , 2018 .

[2]  Anoop Kumar Sood,et al.  Intelligent process model for bead geometry prediction in WAAM , 2018 .

[3]  M. Davidson,et al.  Parameters effect on SS304 beads deposited by wire arc additive manufacturing , 2020 .

[4]  B. Baufeld,et al.  Additive manufacturing of Ti–6Al–4V components by shaped metal deposition: Microstructure and mechanical properties , 2010 .

[5]  Rubén Escribano García,et al.  Using Genetic Algorithms With Multi-Objective Optimization To Adjust Finite Element Models Of Welded Joints , 2018 .

[6]  Américo Scotti,et al.  A scientific application oriented classification for metal transfer modes in GMA welding , 2012 .

[7]  Werner von Seelen,et al.  Intensity and Edge-Based Symmetry Detection Applied to Car-Following , 1992, ECCV.

[8]  F. Veiga,et al.  Metal transfer modes for Wire Arc Additive Manufacturing Al-Mg alloys: Influence of heat input in microstructure and porosity , 2021 .

[9]  Paul Kah,et al.  Advanced gas metal arc welding processes , 2013 .

[10]  Shanben Chen,et al.  A review on wire arc additive manufacturing: Monitoring, control and a framework of automated system , 2020, Journal of Manufacturing Systems.

[11]  Bintao Wu,et al.  A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement , 2018, Journal of Manufacturing Processes.

[12]  Valdemar R. Duarte,et al.  Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM) , 2019, Materials.

[13]  Zengxi Pan,et al.  Wire-feed additive manufacturing of metal components: technologies, developments and future interests , 2015 .

[14]  Xiao Huang,et al.  Effect of wire and arc additive manufacturing (WAAM) process parameters on bead geometry and microstructure , 2019, Additive Manufacturing.

[15]  Farhad Kolahan,et al.  A New Approach for Predicting and Optimizing Weld Bead Geometry in GMAW , 2009 .

[16]  Chengyang Zhang,et al.  Influence of pulsed arc on the metal droplet deposited by projected transfer mode in wire-arc additive manufacturing , 2018, Journal of Materials Processing Technology.

[17]  R. R. Gharieb,et al.  Edge Detection with a Preprocessing Approach , 2014 .

[18]  Lin Wu,et al.  Bead geometry prediction for robotic GMAW-based rapid manufacturing through a neural network and a second-order regression analysis , 2012, Journal of Intelligent Manufacturing.

[20]  Zengxi Pan,et al.  The first step towards intelligent wire arc additive manufacturing: An automatic bead modelling system using machine learning through industrial information integration , 2021, J. Ind. Inf. Integr..

[21]  Lin Wu,et al.  Modeling of bead section profile and overlapping beads with experimental validation for robotic GMAW-based rapid manufacturing , 2013 .

[22]  A. Popovich,et al.  A high-performance WAAM process for Al–Mg–Mn using controlled short-circuiting metal transfer at increased wire feed rate and increased travel speed , 2020 .

[23]  J. Watts,et al.  The influence of build parameters and wire batch on porosity of wire and arc additive manufactured aluminium alloy 2319 , 2018, Journal of Materials Processing Technology.

[24]  Aitzol Lamikiz,et al.  Analysis of the Wall Geometry with Different Strategies for High Deposition Wire Arc Additive Manufacturing of Mild Steel , 2020, Metals.

[25]  Sadek Crisóstomo Absi Alfaro,et al.  Real-Time Measurement of Width and Height of Weld Beads in GMAW Processes , 2016, Sensors.

[26]  Jun Xiong,et al.  Online measurement of bead geometry in GMAW-based additive manufacturing using passive vision , 2013 .

[27]  Jialuo Ding,et al.  Effect of arc mode in cold metal transfer process on porosity of additively manufactured Al-6.3%Cu alloy , 2015 .

[28]  P. Murray.  Selecting parameters for GMAW using dimensional analysis. Regression and dimensional analysis of experimental data established relationships between welding parameters and process variables , 2002 .

[29]  A. Lamikiz,et al.  High deposition wire arc additive manufacturing of mild steel: Strategies and heat input effect on microstructure and mechanical properties , 2020 .

[30]  Fang Li,et al.  Thermoelectric Cooling-Aided Bead Geometry Regulation in Wire and Arc-Based Additive Manufacturing of Thin-Walled Structures , 2018 .

[31]  Q. Gao,et al.  Microstructure and properties of Al alloy ER5183 deposited by variable polarity cold metal transfer , 2019, Journal of Materials Processing Technology.

[32]  K. Venkatarao.  The use of teaching-learning based optimization technique for optimizing weld bead geometry as well as power consumption in additive manufacturing , 2021 .

[33]  Jianhao Wang,et al.  Comparative Study of Droplet Transfer Modes on Appearance, Microstructure, and Mechanical Properties of Weld during Pulsed GMAW , 2020, Metals.

[34]  Alfredo Suárez,et al.  Study on Arc Welding Processes for High Deposition Rate Additive Manufacturing , 2018 .

[35]  A. Addison,et al.  Wire + Arc Additive Manufacturing , 2016 .

[36]  Yi Luo,et al.  Energy characteristics of droplet transfer in wire-arc additive manufacturing based on the analysis of arc signals , 2019, Measurement.