Abstract
Wire arc additive manufacturing allows the production of metallic parts by the deposition of weld beads using arc-welding technologies. This low-cost additive manufacturing technology has the ability to manufacture large-scale parts at a high deposition rate. However, the quality of the obtained parts is greatly affected by the various thermal phenomena present during the manufacturing process. Numerical simulation remains an effective tool for studying such phenomena. In this paper, a new finite element method is proposed in order to model material deposition and heat input in WAAM process. This method allows to gradually construct the mesh representing the deposited zones along the deposition path. The heat source model from Goldak is adapted and combined with the proposed material deposition technique considering the power distribution between the filler material and the molten pool. The effectiveness of the new method is validated through a set of experimentations, one of which is detailed in this paper.
Similar content being viewed by others
References
Vayre, B., Vignat, F., Villeneuve, F.: Metallic additive manufacturing: state-of-the-art review and prospects. Mech. Ind. 13(2), 89–96 (2012). https://doi.org/10.1051/meca/2012003
Lopes Nunes, M., Pereira, A.C., Alves, A.C.: Smart products development approaches for industry 4.0. Proced. Manuf. 13, 1215–1222 (2017). https://doi.org/10.1016/j.promfg.2017.09.035
Liberini, M., et al.: Selection of optimal process parameters for wire arc additive manufacturing. Proced. CIRP 62, 470–474 (2017). https://doi.org/10.1016/j.procir.2016.06.124
Derekar, K.S.: A review of wire arc additive manufacturing and advances in wire arc additive manufacturing of aluminium. Mater. Sci. Technol. 34(8), 895–916 (2018). https://doi.org/10.1080/02670836.2018.1455012
Zhao, Y., Jia, Y., Chen, S., Shi, J., Li, F.: Process planning strategy for wire-arc additive manufacturing: thermal behavior considerations. Addit. Manuf. 32, 100935 (2020). https://doi.org/10.1016/j.addma.2019.100935
Montevecchi, F., Venturini, G., Grossi, N., Scippa, A., Campatelli, G.: Heat accumulation prevention in wire-arc-additive-manufacturing using air jet impingement. Manuf. Lett. 17, 14–18 (2018). https://doi.org/10.1016/j.mfglet.2018.06.004
Wang, Z., Zimmer-Chevret, S., Léonard, F., et al.: Prediction of bead geometry with consideration of interlayer temperature effect for CMT-based wire-arc additive manufacturing. Weld. World 65, 2255–2266 (2021). https://doi.org/10.1007/s40194-021-01192-2
Béraud, N., Vignat, F., Villeneuve, F., Dendievel, R.: Improving dimensional accuracy in EBM using beam characterization and trajectory optimization. Addit. Manuf. 14, 1–6 (2017). https://doi.org/10.1016/j.addma.2016.12.002
Vignat, F., Béraud, N., Villeneuve, F.: Rapid thermal simulation of powder bed additive manufacturing.In: 2018 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM), pp. 1498–1502. Bangkok, (2018), doi: https://doi.org/10.1109/IEEM.2018.8607695
Stavropoulos, P., Foteinopoulos, P.: Modelling of additive manufacturing processes: a review and classification. Manuf. Rev. 5, 2 (2018). https://doi.org/10.1051/mfreview/2017014
Xiong, J., Lei, Y., Li, R.: Finite element analysis and experimental validation of thermal behavior for thin-walled parts in GMAW-based additive manufacturing with various substrate preheating temperatures. Appl. Therm. Eng. 126, 43–52 (2017). https://doi.org/10.1016/j.applthermaleng.2017.07.168
Xiong, J., Li, R., Lei, Y., Chen, H.: Heat propagation of circular thin-walled parts fabricated in additive manufacturing using gas metal arc welding. J. Mater. Process. Technol. 251, 12–19 (2018). https://doi.org/10.1016/j.jmatprotec.2017.08.007
Montevecchi, F., Venturini, G., Scippa, A., Campatelli, G.: Finite element modelling of wire-arc-additive-manufacturing process. Proced. CIRP 55, 109–114 (2016). https://doi.org/10.1016/j.procir.2016.08.024
Montevecchi, F., Venturini, G., Grossi, N., Scippa, A., Campatelli, G.: Finite element mesh coarsening for effective distortion prediction in wire arc additive manufacturing. Addit. Manuf. 18, 145–155 (2017). https://doi.org/10.1016/j.addma.2017.10.010
Ding, J., et al.: Thermo-mechanical analysis of wire and arc additive layer manufacturing process on large multi-layer parts. Comput. Mater. Sci. 50(12), 3315–3322 (2011). https://doi.org/10.1016/j.commatsci.2011.06.023
Michaleris, P.: Modeling metal deposition in heat transfer analyses of additive manufacturing processes. Finite Elem. Anal. Des. 86, 51–60 (2014). https://doi.org/10.1016/j.finel.2014.04.003
Hu, J., Tsai, H.L.: Heat and mass transfer in gas metal arc welding. Part I: the arc. Int. J. Heat Mass Transf. 50(5–6), 833–846 (2007). https://doi.org/10.1016/j.ijheatmasstransfer.2006.08.025
Goldak, J., Chakravarti, A., Bibby, M.: A new element model for welding heat source. Metall. Mater. Trans. B 15, 299–305 (1984). https://doi.org/10.1007/BF02667333
Chergui, A., Beraud, N., Vignat, F., Villeneuve, F.: Finite element modeling and validation of metal deposition in wire arc additive manufacturing. In: Roucoules, L., Paredes, M., Eynard, B., Morer Camo, P., Rizzi, C. (eds.) Advances on mechanics, design engineering and manufacturing III. JCM 2020. Lecture notes in mechanical engineering. Springer, Cham (2021). https://doi.org/10.1007/978-3-030-70566-4_11
DuPont, J.N., Marder, A.R.: Thermal efficiency of arc welding processes. Weld. J.-Incl. Weld. Res. Suppl. 74(12), 406s-416s (1995)
El-Sayed, M.M., Shash, A.Y., Abd-Rabou, M.: Finite element modeling of aluminum alloy AA5083-O friction stir welding process. J. Mater. Process. Technol. 252, 13–24 (2018). https://doi.org/10.1016/j.jmatprotec.2017.09.008
Manokruang, S., Vignat, F., Museau, M., Limousin, M.: Process parameters effect on weld beads geometry deposited by wire and arc additive manufacturing (WAAM). In: Roucoules, L., Paredes, M., Eynard, B., Morer Camo, P., Rizzi, C. (eds.) Advances on mechanics, design engineering and manufacturing III. JCM 2020. Lecture notes in mechanical engineering. Springer, Cham (2021)
Funding
The work presented was funded by Univ. Grenoble Alpes.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflicts of interest
The author declare that they have no conflict of interest.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Chergui, A., Villeneuve, F., Béraud, N. et al. Thermal simulation of wire arc additive manufacturing: a new material deposition and heat input modelling. Int J Interact Des Manuf 16, 227–237 (2022). https://doi.org/10.1007/s12008-021-00824-7
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12008-021-00824-7