Journals →  CIS Iron and Steel Review →  2024 →  #1 →  Back

Additive Technologies
ArticleName Porosity reduction in metal with hybrid wire and arc additive manufacturing technology (WAAM)
DOI 10.17580/cisisr.2024.01.14
ArticleAuthor A. I. Karlina, V. V. Kondratyev, A. E. Balanovskiy, N. A. Astafyeva, E. A. Yamshchikova
ArticleAuthorData

Moscow State University of Civil Engineering (Moscow, Russia)

A. I. Karlina, Cand. Eng., Scientific Researcher, e-mail: karlinat@mail.ru

 

A. P. Vinogradov Institute of Geochemistry of the Siberian Branch of the Russian Academy of Sciences (Irkutsk, Russia)

V. V. Kondratyev, Cand. Eng., Senior Scientific Researcher

 

Irkutsk National Research Technical University (Irkutsk, Russia)
A. E. Balanovskiy, Cand. Eng., Associate Prof., Head of the Dept. of Material Science, Welding and Additive Technologies
N. A. Astafyeva, Cand. Eng., Associate Prof.
E. A. Yamshchikova, Postgraduate Student

Abstract

Among different additive manufacturing (AM) methods, wire and arc additive manufacturing (WAAM) is the most suitable for manufacture of large-size metal components due to high deposition rates, which are rather higher than that for a powder laser and electron beam technology. AM processes are connected with high residual stresses and deformations due to excessive heat supply and high deposition rate. Influence of the process conditions, such as supplied energy, wire feed rate, welding speed, features and sequence of deposition etc., on thermal prehistory and resulting residual stresses in machine components (which were processed via additive-modular treatment), requires additional understanding. Additionally, low accuracy and surface cleanness during the process restricts use of AM technology with wire addition. This paper describes a hybrid (additive + subtractive) manufacturing approach for a steel component based on wire and arc additive manufacturing. The hybrid wire and arc additive manufacturing (WAAM) is used to describe a sequence of manufacturing steps. The main idea of the suggested approach is minimization of porosity in WAAM production process of machine components; as a result, quality of deposed metal layer improves. A steel wall was produced by hybrid (additive + subtractive) manufacturing. The non-destructive testing methods (penetrant inspection, ultrasound inspection, and X-ray inspection) were used to confirm high quality of metals.

keywords Hybrid manufacturing, wire and arc additive manufacturing (WAAM), grinding, defects, ultrasound, X-ray
References

1. Jafari D., Vaneker T. H. J., Gibson I. Wire and arc additive manufacturing: Opportunities and challenges to control the quality and accuracy of manufactured parts. Materials & Design. 2021. Vol. 202. 109471. DOI: 10.1016/j.matdes.2021.109471
2. Rodrigues T. A., Duarte V., Miranda R. M., Santos T. G., Oliveira J. P. Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM). Materials. 2019. Vol. 12. No. 7. 1121. DOI: 10.3390/ma12071121
3. Donghong Ding, Pan Zengxi, Cuiuri D., Huijun Li. Wire-feed additive manufacturing of metal components: Technologies, developments and future interests. International Joural of Advanced Manufacturing Technology. 2015. Vol. 81. pp. 465–481. DOI: 10.1007/s00170-015-7077-3
4. Bandyopadhyay A., Heer B. Additive manufacturing of multi-material structures. Materials Scence and Engineering Report. 2018. Vol. 129. pp. 1–16. DOI: 10.1016/j.mser.2018.04.001
5. Wu Bintao, Pan Zengxi, Donghong Ding, Cuiuri D., Huijun Li, Jing Xu, Norrish J. A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement. Journal of Manufacturing Processes. 2018. Vol. 35. pp. 127–139. DOI: 10.1016/j.jmapro.2018.08.001
6. Pan Zengxi, Donghong Ding, Wu B., Cuiuri D., Huijun Li, Norrish J. Arc Welding Processes for Additive Manufacturing: A Review. In: Transactions on Intelligent Welding Manufacturing. Springer, Singapore, 2018. pp. 3–24. DOI: 10.1007/978-981-10-5355-9_1
7. Oliveira J. P., Santos T. G., Miranda R. M. Revisiting fundamental welding concepts to improve additive manufacturing: From theory to practice. Progress in Materials Science. 2019. Vol. 107. 100590. DOI: 10.1016/j.pmatsci.2019.100590
8. DebRoy T., Wei H. L., Zuback J. S., Mukherjee T., Elmer J. W., Milewski J. O., Beese A. M., Wilson-Heid A., De A., Zhang W. Additive manufacturing of metallic components – Process, structure and properties. Progress in Materials Science. 2018. Vol. 92. pp. 112–224. DOI: 10.1016/j.pmatsci.2017.10.001
9. Jun Xiong, Guangjun Zhang. Adaptive control of deposited height in GMAW-based layer additive manufacturing. Journal of Materials Processing Technology. 2014. Vol. 214. pp. 962–968. DOI: 10.1016/j.jmatprotec.2013.11.014
10. Ding J., Colegrove P., Martina F., Williams S., Wiktotovicz R., Palt M. R. Development of a laminar flow local shielding device for wire+arc additive manufacture. Journal of Materials Processing Technology. 2015. Vol. 226. pp. 99–105. DOI: 10.1016/j.jmatprotec.2015.07.005
11. Yong-Ak Song, Sehyung Park, Doosun Choi, Haesung Jee. 3D welding and milling: Part I–a direct approach for freeform fabrication of metallic prototypes. International Journal of Machine Tools and Manufacture. 2005. Vol. 45. No. 9. pp. 1057–1062. DOI: 10.1016/j.ijmachtools.2004.11.021
12. Karunakaran K. P., Suryakumar S., Pushpa V., Akula S. Low cost integration of additive and subtractive processes for hybrid layered manufacturing. Robotics and Computer-Integrated Manufacturing. 2010. Vol. 26. No. 5. pp. 490–499. DOI: 10.1016/j.rcim.2010.03.008
13. Honeycutt A., Mhatre P., Gibson B., Smith S., Richardson B. Iterative hybrid manufacture of a titanium alloy component. Manufacturing Letters. 2021. Vol. 29. pp. 90–93. DOI: 10.1016/j.mfglet.2021.07.003
14. Duarte V. R., Rodrigues T. A., Schell N., Miranda R. M., Oliveira J. P., Santos T. G. Hot forging wire and arc additive manufacturing (HF-WAAM). Additive Manufacturing. 2020. Vol. 35. 101193. DOI: 10.1016/j.addma.2020.101193
15. Hybrid Machines 3D Printing. LASIMM Project. Available at: http://www.lasimm.eu (accessed April 23, 2021).
16. Kulikov A. A., Balanovskii A. E., Grechneva M. V. Effect of Wire Arc Additive Manufacturing Process Parameters on Deposition Behavior of Steel. Proceedings of the 6th International Conference on Industrial Engineering (ICIE 2020). ICIE 2021. Lecture Notes in Mechanical Engineering. Springer, Cham. pp. 426–435. DOI: 10.1007/978-3-030-54817-9_50
17. Balanovskiy A. E., Astafyeva N. A., Kondratyev V. V., Karlina A. I. Study of mechanical properties of C–Mn–Si composition after wire-arc additive manufacturing (WAAM). CIS Iron and Steel Review. 2021. Vol. 22. pp. 66–71.
18. Balanovskiy A. E., Astafyeva N. A., Kondratyev V. V., Karlina A. I. Study of impact strength of C–Mn–Si composition metal after wire-arc additive manufacturing (WAAM). CIS Iron and Steel Review. 2022. Vol. 24. pp. 67–73.
19. Chaturvedi M., Scutelnicu E., Rusu C. C., Mistodie L. R., Mihailescu D., Subbiah A. V. Wire Arc Additive Manufacturing: Review on Recent Findings and Challenges in Industrial Applications and Materials Characterization. Metals. 2021. No. 11. 939. DOI: 10.3390/met11060939
20. Zhao Y. et al. Effect of shielding gas on the metal transfer and weld morphology in pulsed current MAG welding of carbon steel. Journal of Materials Processing Technology. 2018. Vol. 262. pp. 382–391.
21. Costanza G., Sili A., Tata M. E. Weldability of austenitic stainless steel by metal arc welding with different shielding gas. Procedia Structural Integrity. 2016. Vol. 2. pp. 3508–3514.
22. Ding J. et al. Development of a laminar flow local shielding device for wire+ arc additive manufacture. Journal of Materials Processing Technology. 2015. Vol. 226. pp. 99–105.
23. Xu X. et al. Oxide accumulation effects on wire+ arc layer-bylayer additive manufacture process. Journal of Materials Processing Technology. 2018. Vol. 252. pp. 739–750.

Full content Porosity reduction in metal with hybrid wire and arc additive manufacturing technology (WAAM)
Back