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Air Jet Cooling Applied to Wire Arc Additive Manufacturing: A Hybrid Numerical-Experimental Investigation

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Selected Topics in Manufacturing

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

Abstract

WAAM (Wire Arc Additive Manufacturing) is a metal additive manufacturing process based on gas metal arc welding which enables to create large parts with a high deposition rate. WAAM is prone to the heat accumulation issue, i.e. a progressive increase of the workpiece internal energy due to the high heat input of the welding process, which can cause defects such as part structural collapse, uneven layers geometry or non-homogenous microstructure. A promising technique to mitigate such issue is to use an air jet impinging on the deposited material to increase the convective heat transfer. This paper presents an analysis of air jet impingement performances by means of a hybrid numerical-experimental approach. Different samples of a test case are manufactured using free convection cooling, air jet impingement and different interlayer idle times. Substrate temperatures are measured and compared with the results of a finite element simulation to assess its accuracy. The performances of air jet impingement are analyzed in terms of measured substrate temperatures and of simulated interlayer temperature, evaluated at the top of each layer. The results highlight that air jet impingement has a significant impact on the process, limiting the progressive increase of interlayer temperature compared with free convection cooling.

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Abbreviations

A, B, C:

Empirical factors to calculate jet impingement heat transfer coefficient

l :

Nozzle to target surface standoff distance

Nu :

Nusselt number, i.e. dimensionless heat transfer coefficient

Ø:

Angular coordinate for jet impingement heat transfer coefficient calculation

r :

Radial coordinate for jet impingement heat transfer coefficient calculation

d :

Air nozzle diameter

Re :

Reynolds number of the impinging air jet

α:

Angle between the jet axis and the target surface

Δy:

Nozzle offset along the y coordinate

Δz:

Nozzle to torch offset along the z coordinate

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Authors and Affiliations

  1. Department of Industrial Engineering, University of Firenze, Via di Santa Marta 3, 50139, Firenze, Italy

    Filippo Montevecchi & Gianni Campatelli

  2. Welding and Related Techniques Laboratory, Department of Mechanical Engineering, Federal University of Rio Grande do Sul, Porto Alegre, RS, Brazil

    William Hackenhaar

Authors
  1. Filippo Montevecchi
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  2. William Hackenhaar
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  3. Gianni Campatelli
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Corresponding author

Correspondence to Gianni Campatelli .

Editor information

Editors and Affiliations

  1. Dipartimento di Ingegneria Meccanica e Industriale, Università di Brescia, Brescia, Italy

    Elisabetta Ceretti

  2. Mechanical Engineering Department, Politecnico di Milano, Milano, Italy

    Tullio Tolio

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Montevecchi, F., Hackenhaar, W., Campatelli, G. (2021). Air Jet Cooling Applied to Wire Arc Additive Manufacturing: A Hybrid Numerical-Experimental Investigation. In: Ceretti, E., Tolio, T. (eds) Selected Topics in Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-57729-2_6

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  • DOI: https://doi.org/10.1007/978-3-030-57729-2_6

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-030-57728-5

  • Online ISBN: 978-3-030-57729-2

  • eBook Packages: EngineeringEngineering (R0)

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