Computational welding simulation of a plasma wire arc additive manufacturing process for high-strength steel

Figures & data

Figure 1. FE-Model for heat source calibration.

Table 1. Chemical composition in mass% of modified C55 (EN ISO 683-1, 2018) and 3Dprint AM 80 HD (Voestalpine Böhler Welding Austria GmbH, 2023) nominal according to datasheet.

	C	Si	Mn	P	S	Cr	Cu	Mo	Ni	V
Modified C55	0.56	0.40	0.80	0.02	0.015	0.30	0.30	0.08	0.30	0.06
3Dprint AM 80 HD	0.09	0.40	1.70	–	–	0.35	–	0.60	2.00	–

Figure 2. Double elliptical Goldak heat source model (Rubio-Ramirez, Giarollo, Mazzaferro, & Mazzaferro, 2021).

Figure 3. Gaussian heat source model.

Table 2. Welding parameters for experiment.

I [A]	U [V]	$v_s$ [mm/s]	$v_D$ [mm/s]	$\dot{{ V}_s}$ [l/min]	$\dot{{ V}_P}$ [l/min]
260	22.4	4	48	15	1.5

Figure 4. Cross-sectional micrograph transvers to weld seam.

Figure 5. Deviation of the simulation from the experimentally determined melt pool geometry (double elliptical heat source).

Figure 6. Deviation of the simulation from the experimentally determined melt pool geometry (Gaussian heat source).

Figure 7. Temperature profiles simulation no. 27 and experiment.

Table 3. Heat source parameters.

voltage U [V]	22.4
current I [A]	260
welding speed $v_s$ [mm/s]	4
efficiency η [%]	55
circle radius $r_s$ [mm]	8
Gaussian parameter M [-]	1.5

Figure 8. 3D temperature field validated heat source.

Figure 9. (a) Isothermal temperature field, (b) transverse temperature distribution.

Figure 10. Surface deviation 4 times magnified.

Figure 11. Comparison of distortion on sample backside.

EN ISO 683-1. (2018). Heat-treatable steels, alloy steels and free-cutting steels Part 1: Non-alloy steels for quenching and tempering.

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Voestalpine Böhler Welding Austria GmbH. Product datasheet: 3Dprint AM 80 HD. Accessed: June 21, 2023. [Online]. Retrieved from http://www.vabw-service.com/voestalpine/index.php?changeLang=de&qid=10

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Rubio-Ramirez, C., Giarollo, D. F., Mazzaferro, J. E., & Mazzaferro, C. P. (2021). Prediction of angular distortion due GMAW process of thin-sheets Hardox 450® steel by numerical model and artificial neural network. Journal of Manufacturing Processes, 68, 1202–1213. doi:10.1016/j.jmapro.2021.06.045

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