297
Views
0
CrossRef citations to date
0
Altmetric
Article

Effect of electrode materials and process parameters on deposition characteristics during GMAW-AM

ORCID Icon, & ORCID Icon
Pages 1809-1822 | Received 16 Feb 2023, Accepted 19 Apr 2023, Published online: 28 May 2023

References

  • Derekar, K. S. A Review of Wire Arc Additive Manufacturing and Advances in Wire Arc Additive Manufacturing of Aluminium. Mater. Sci. Technol. 2018, 34(8), 895–916. DOI: 10.1080/02670836.2018.1455012.
  • Pattanayak, S.; Sahoo, S. K. Gas Metal Arc Welding Based Additive Manufacturing—A Review. CIRP J. Manuf. Sci. Technol. 2021, 33, 398–442. DOI: 10.1016/j.cirpj.2021.04.010.
  • Jimenez-Ordonez, D. C.; Martinez-Hernandez, A. L.; Martinez-Barrera, G.; Velasco-Santos, C. Design and 3D Printing Manufacturing of Complex Structures for Airflow Evaluation. Mater. Manuf. Process. 2022, 38(8), 980–988. DOI: 10.1080/10426914.2022.2116034.
  • Kechagias, J.; Chaidas, D. Fused Filament Fabrication Parameter Adjustments for Sustainable 3D Printing. Mater. Manuf. Process. 2023, 38(8), 933–940. DOI: 10.1080/10426914.2023.2176872.
  • Kumar, P.; Sharma, S. K.; Singh, R. K. R. Recent Trends and Future Outlooks in Manufacturing Methods and Applications of FGM: A Comprehensive Review. Mater. Manuf. Process. 2022, 38(9), 1033–1067. DOI: 10.1080/10426914.2022.2075892.
  • Kechagias, J. Investigation of LOM Process Quality Using Design of Experiments Approach. Rapid Prototyp. J. 2007, 13(5), 316–323. DOI: 10.1108/13552540710824823.
  • Ravi, G.; Murugan, N.; Arulmani, R. Microstructure and Mechanical Properties of Inconel-625 Slab Component Fabricated by Wire Arc Additive Manufacturing. Mater. Sci. Technol. 2020, 36(16), 1785–1795. DOI: 10.1080/02670836.2020.1836737.
  • Omiyale, B. O.; Olugbade, T. O.; Abioye, T. E.; Farayibi, P. K. Wire Arc Additive Manufacturing of Aluminium Alloys for Aerospace and Automotive Applications: A Review. Mater. Sci. Technol. 2022, 38(7), 391–408. DOI: 10.1080/02670836.2022.2045549.
  • Zhang, Y.; Xiong, J.; Li, D.; Zhang, G. Height Control in GMA-AM Using External Wire as Controlling Variable. Mater. Manuf. Process. 2022, 38(8), 971–979. DOI: 10.1080/10426914.2022.2089892.
  • Feier, A.; Buta, I.; Florica, C.; Blaga, L. Optimization of Wire Arc Additive Manufacturing (Waam) Process for the Production of Mechanical Components Using a CNC Machine. Materials. 2023, 16, 17. DOI: 10.3390/ma16010017.
  • 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, 12, 1121. DOI: 10.3390/ma12071121.
  • Wu, W.; Xue, J.; Zhang, Z.; Yao, P. Comparative Study of 316L Depositions by Two Welding Current Processes. Mater. Manuf. Process. 2019, 34(13), 1502–1508. DOI: 10.1080/10426914.2019.1643473.
  • Lambiase, F.; Scipioni, S. I.; Paoletti, A. Accurate Prediction of the Bead Geometry in Wire Arc Additive Manufacturing Process. Int. J. Adv. Manuf. Technol. 2022, 119, 7629–7639. DOI: 10.1007/s00170-021-08588-w.
  • Chaurasia, P. K.; Goecke, S. F.; De, A. Real-Time Monitoring of Temperature Field, Metal Transfer and Cooling Rate During Gas Metal Arc-Directed Energy Deposition. Sci. Technol. Weld. Join. 2022, 27(7), 512–521. DOI: 10.1080/13621718.2022.2080447.
  • Tang, S.; Wang, G.; Song, H.; Li, R.; Zhang, H. A Novel Method of Bead Modeling and Control for Wire and Arc Additive Manufacturing. Rapid Prototyp. J. 2021, 27(2), 311–320. DOI: 10.1108/RPJ-05-2020-0097.
  • Cao, Y.; Zhu, S.; Liang, X.; Wang, W. Overlapping Model of Beads and Curve Fitting of Bead Section for Rapid Manufacturing by Robotic MAG Welding Process. Robot. Comput. Integr. Manuf. 2011, 27(3), 641–645. DOI: 10.1016/j.rcim.2010.11.002.
  • Suryakumar, S.; Karunakaran, K. P.; Bernard, A.; Chandrasekhar, U.; Raghavender, N.; Sharma, D. Weld Bead Modeling and Process Optimization in Hybrid Layered Manufacturing. CAD Comput. Aided Des. 2011, 43(4), 331–344. DOI: 10.1016/j.cad.2011.01.006.
  • Xiong, J.; Zhang, G.; Gao, H.; Wu, L. Modeling of Bead Section Profile and Overlapping Beads with Experimental Validation for Robotic GMAW-Based Rapid Manufacturing. Robot. Comput. Integr. Manuf. 2013, 29, 417–423. DOI: 10.1016/j.rcim.2012.09.011.
  • Ding, D.; Pan, Z.; Cuiuri, D.; Li, H. A Multi-Bead Overlapping Model for Robotic Wire and Arc Additive Manufacturing (WAAM). Robot. Comput. Integr. Manuf. 2015, 31, 101–110. DOI: 10.1016/j.rcim.2014.08.008.
  • Li, Y.; Han, Q.; Zhang, G.; Horvath, I. A Layers-Overlapping Strategy for Robotic Wire and Arc Additive Manufacturing of Multi-Layer Multi-Bead Components with Homogeneous Layers. Int. J. Adv. Manuf. Technol. 2018, 96, 3331–3344. DOI: 10.1007/s00170-018-1786-3.
  • Rajeev, G. P.; Kamaraj, M.; Bakshi, S. R. Effect of Correction Parameters on Deposition Characteristics in Cold Metal Transfer Welding. Mater. Manuf. Process. 2019, 34(11), 1205–1216. DOI: 10.1080/10426914.2019.1628260.
  • Liu, G.; Xiong, J. External Filler Wire Based GMA-AM Process of 2219 Aluminum Alloy. Mater. Manuf. Process. 2020, 35(11), 1268–1277. DOI: 10.1080/10426914.2020.1779936.
  • Liu, G.; Xiong, J.; Li, D.; Zhang, G. Effect of Heat Input on Auxiliary Wire GMA-AM TiAl Alloys. Mater. Manuf. Process. 2022, 1–10. DOI: 10.1080/10426914.2022.2072878.
  • Ortega, A. G.; Galvan, L. C.; Beaume, F. D.; Mezrag, B.; Rouquette, S. Effect of Process Parameters on the Quality of Aluminium Alloy Al5Si Deposits in Wire and Arc Additive Manufacturing Using a Cold Metal Transfer Process. Sci. Technol. Weld. Join. 2018, 23(4), 316–332. DOI: 10.1080/13621718.2017.1388995.
  • Ortega, A. G.; Galvan, L. C.; Salem, M.; Moussaoui, K.; Segonds, S.; Rouquette, S.; Beaume, F. D. Characterisation of 4043 Aluminium Alloy Deposits Obtained by Wire and Arc Additive Manufacturing Using a Cold Metal Transfer Process. Sci. Technol. Weld. Join. 2019, 24(6), 538–547. DOI: 10.1080/13621718.2018.1564986.
  • Gullipalli, C.; Thawari, N.; Burad, P.; Gupta, T. V. K. Residual Stresses and Distortions in Additive Manufactured Inconel 718. Mater. Manuf. Process. 2023, 1–12. DOI: 10.1080/10426914.2023.2165663.
  • Wu, W.; Xue, J.; Yao, P. A Comparative Study on Single- and Double-Arc Deposition Processes. Mater. Manuf. Process. 2020, 35(3), 346–353. DOI: 10.1080/10426914.2020.1726947.
  • Osintsev, K.; Konovalov, S.; Gromov, V.; Panchenko, I.; Ivanov, Y. Microstructural and Mechanical Characterisation of Non-Equiatomic Al2.1Co0.3Cr0.5FeNi2.1 High-Entropy Alloy Fabricated via Wire-Arc Additive Manufacturing. Philos. Mag. Lett. 2021, 101(9), 353–359. DOI: 10.1080/09500839.2021.1936257.
  • Elmer, J. W.; Gibbs, G. Mechanical Rolling and Annealing of Wire-Arc Additively Manufactured Stainless Steel Plates. Sci. Technol. Weld. Join. 2022, 27(1), 14–21. DOI: 10.1080/13621718.2021.1996003.
  • Bellamkonda, P. N.; Sudersanan, M.; Visvalingam, B. A Study on Tensile Properties and Microstructural Characteristics of Wire Arc Additive Manufactured Low Carbon Steel Cylindrical Components. Weld. Int. 2022, 36(8), 443–454. DOI: 10.1080/09507116.2022.2097897.
  • Zhang, Z.; Wang, Q.; Li, Z.; Wang, X.; Song, G. Research on 316 Stainless Steel Low-Power Pulsed Laser-Induced Arc Additive Manufacturing by Different Deposition Routes. Weld. Int. 2022, 36(11), 679–692. DOI: 10.1080/09507116.2022.2152761.
  • Sarabia, L. A.; Ortiz, M. C. Response Surface Methodology. Compr. Chemom. 2009, 1, 345–390. DOI: 10.1016/B978-044452701-1.00083-1.
  • Sarathchandra, D. T.; Davidson, M. J.; Visvanathan, G. Parameters Effect on SS304 Beads Deposited by Wire Arc Additive Manufacturing. Mater. Manuf. Process. 2020, 35(7), 852–858. DOI: 10.1080/10426914.2020.1743852.
  • Nagasai, B. P.; Malarvizhi, S.; Balasubramanian, V. A Study on Wire Arc Additive Manufacturing of 308L Austenitic Stainless Steel Cylindrical Components: Optimization, Microstructure and Mechanical Properties. Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 2022. DOI: 10.1177/09544054221129471.
  • Sahoo, A. K.; Sahoo, S. K.; Pattanayak, S.; Moharana, M. K. Ultrasonic Vibration Assisted Turning of Inconel 825: An Experimental Analysis. Mater. Manuf. Process. 2023, 1–15. DOI: 10.1080/10426914.2023.2165675.
  • Chaudhari, R.; Parmar, H.; Vora, J.; Patel, V. K. Parametric Study and Investigations of Bead Geometries of GMAW-Based Wire–Arc Additive Manufacturing of 316L Stainless Steels. Metals. 1232, 2022, 12. DOI: 10.3390/met12071232.
  • Gokhale, N. P.; Kala, P. Development of a Deposition Framework for Implementation of a Region-Based Adaptive Slicing Strategy in Arc-Based Metal Additive Manufacturing. Rapid Prototyp. J. 2022, 28(3), 466–478. DOI: 10.1108/RPJ-10-2020-0246.
  • Xu, G.; Xu, X.; Lv, X.; Liu, L. A Novel Modification to TW-GIA for Controlling Heat Input of Base Metal. Mater. Manuf. Process. 2022, 38(2), 220–227. DOI: 10.1080/10426914.2022.2116039.
  • Elsokaty, A.; Oraby, O.; Sadek, S.; Salem, H. G. Influence of Wire Arc Additive Manufacturing Beads’ Geometry and Building Strategy: Mechanical and Structural Behavior of ER70S-6 Prismatic Blocks. J. Manuf. Mater. Process. 2023, 7(1), 3. DOI: 10.3390/jmmp7010003.
  • Yildiz, A. S.; Davut, K.; Koc, B.; Yilmaz, O. Wire Arc Additive Manufacturing of High-Strength Low Alloy Steels: Study of Process Parameters and Their Influence on the Bead Geometry and Mechanical Characteristics. Int. J. Adv. Manuf. Technol. 2020, 108, 3391–3404. DOI: 10.1007/s00170-020-05482-9.
  • Teixeira, F. R.; Scotti, F. M.; Reis, R. B.; Scotti, A. Effect of the CMT Advanced Process Combined with an Active Cooling Technique on Macro and Microstructural Aspects of Aluminum WAAM. Rapid Prototyp. J. 2021, 27(6), 1206–1219. DOI: 10.1108/RPJ-11-2020-0285.
  • Ahsan, M. R. U.; Tanvir, A. N. M.; Ross, T.; Elsawy, A.; Oh, M. -S.; Kim, D. B. Fabrication of Bimetallic Additively Manufactured Structure (BAMS) of Low Carbon Steel and 316L Austenitic Stainless Steel with Wire + Arc Additive Manufacturing. Rapid Prototyp. J. 2020, 26(3), 519–530. DOI: 10.1108/RPJ-09-2018-0235.
  • Padilha, A. F.; Tavares, C. F.; Martorano, M. A. Delta Ferrite Formation in Austenitic Stainless Steel Castings. Mater. Sci. Forum. 2013, 730–732, 733–738. DOI: 10.4028/ww.scientific.net/MSF.730-732.733.
  • Gowthaman, P. S.; Jeyakumar, S.; Sarathchandra, D. T. Influence of Heat Input on Microstructure and Mechanical Behaviour of Austenitic Stainless Steel 316L Processed in Wire and Arc Additive Manufacturing. Proc. Inst. Mech. Eng. Part E J. Process Mech. Eng. 2022. DOI: 10.1177/09544089221100214.
  • Raut, L. P.; Taiwade, R. V. Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Bimetallic Structure of Austenitic Stainless Steel and Low Carbon Steel. J. Mater. Eng. Perform. 2022, 31, 8531–8541. DOI: 10.1007/s11665-022-06856-8.
  • Wu, W.; Xue, J.; Xu, W.; Lin, H.; Tang, H.; Yao, P. Parameters Optimization of Auxiliary Gas Process for Double-Wire SS316L Stainless Steel Arc Additive Manufacturing. Metals. 2021, 11(2), 190. DOI: 10.3390/met11020190.
  • Pattanayak, S.; Sahoo, S. K.; Sahoo, A. K. Experimental Investigation on Deposits of ER70S-6 Wire on SiO2 Substrate Using Non-Transferred Arc-Based Wire Arc Additive Manufacturing. Int. J. Adv. Manuf. Technol. 2022, 123, 3527–3552. DOI: 10.1007/s00170-022-10499-3.

Reprints and Corporate Permissions

Please note: Selecting permissions does not provide access to the full text of the article, please see our help page How do I view content?

To request a reprint or corporate permissions for this article, please click on the relevant link below:

Academic Permissions

Please note: Selecting permissions does not provide access to the full text of the article, please see our help page How do I view content?

Obtain permissions instantly via Rightslink by clicking on the button below:

If you are unable to obtain permissions via Rightslink, please complete and submit this Permissions form. For more information, please visit our Permissions help page.