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Numerical simulation and experimental investigation of temperature distribution during the wire arc additive manufacturing (WAAM) process

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Abstract

Wire arc additive manufacturing (WAAM) has emerged as a notable technology in the past decade, characterized by its cost-effectiveness and high deposition rates for intricate part manufacturing, surpassing traditional processes. In this investigation, numerical simulations were executed to analyze the temperature distribution when constructing a mild steel rectangular wall on a substrate of the same material, employing the WAAM process as the WAAM-built parts are more susceptible to errors by adverse thermal gradients. Experiments were conducted to build mild steel rectangular walls and temperature data were recorded to validate the numerical outcomes. The experimental and numerical results were found to be in good agreement with less than 10% average error. The Interlayer temperature is observed to rise with the addition of each layer, attributed to the accumulation of heat. Substantial thermal gradients are identified in the lower layers in contrast to the upper layers following the formation of the top layers, owing to the gradual buildup of heat in these lower layers.

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Data availability

The data that support the findings of this study will be available from the corresponding author upon reasonable request.

Abbreviations

\(\rho\) :

Conducting medium density

\({C}_{p}\) :

Specific heat of the medium

\({k}_{x}\) :

Thermal conductivity in the x-direction

\({k}_{y}\) :

Thermal conductivity in the y-direction

\({k}_{z}\) :

Thermal conductivity in the z-direction

\(\dot{q}\) :

Rate of heat produced per unit volume

\(t\) :

Time

\(b\) :

Heat source width

\(c\) :

Heat source depth

\({n}_{x, }{n}_{y, }{n}_{z}\) :

Direction cosines of the normal to the surface

\(h\) :

Convective heat transfer coefficient

\({\sigma }_{{\text{st}}}\) :

Stephan’s Boltzmann constant

\({\varepsilon }_{r}\) :

The emissivity of the surface

\({T}_{0}\) :

Ambient temperature

\(\alpha\) :

Absorptivity

\({q}_{r}\) :

Heat flux function

\({f}_{f}\) :

The factor for distributing power to the front of the heat source

\({f}_{{\text{r}}}\) :

The factor for distributing power to the rear of the heat source

\({a}_{{\text{f}}}\) :

Frontal ellipsoid length

\({a}_{{\text{r}}}\) :

Rear ellipsoid length

\(Q\) :

Actual input energy

η :

Efficiency factor of Goldak heat-source model

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee, Uttarakhand, 247667, India

    Deepak Kumar Gupta & Rahul S. Mulik

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Gupta, D.K., Mulik, R.S. Numerical simulation and experimental investigation of temperature distribution during the wire arc additive manufacturing (WAAM) process. Prog Addit Manuf (2024). https://doi.org/10.1007/s40964-024-00647-4

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