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The gap-filling overlapping model for wire and arc additive manufacturing of multi-bead components

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Abstract

Wire and arc additive manufacturing (WAAM) is a promising technology for fabricating large and complex metallic components. In this respect, surface unevenness of parts deposited by WAAM has always been a pressing issue. The improvement of surface unevenness depends on the multi-bead overlapping model. However, due to the asymmetric deposition environment and obstruction of the previous bead, the traditional overlapping model hardly achieves a relatively flat surface. In this study, the gap-filling overlapping model (GOM) based on the alternate overlapping strategy was proposed for WAAM. Based on the principle of equal volume, the model does not need curve fitting and significantly simplifies the calculation process of its mathematical model. Single-bead experiments were performed to capture the shapes of beads. According to two calculation strategies, three-bead experiments were conducted to verify the correctness of the proposed GOM. Five-bead experiments were conducted to compare the GOM and the alternated overlapping model (AOM). The results show the effectiveness of the GOM in various cross-section profiles of beads. The five-bead sample deposited by the GOM achieves better surface flatness and a larger effective area than the AOM.

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Funding

This work was supported by the Natural Science Foundation of Shanghai (grant no. 20ZR1422600).

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Authors and Affiliations

  1. School of Mechanical and Automobile Engineering, Shanghai University of Engineering Science, 333 Longteng Road, Shanghai, 201620, China

    Jun Zhang, Yanfeng Xing, Juyong Cao, Xiaobing Zhang & Fuyong Yang

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  1. Jun Zhang
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  2. Yanfeng Xing
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  3. Juyong Cao
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  4. Xiaobing Zhang
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Contributions

Conceptualization, methodology, software, validation, visualization, formal analysis, investigation, data curation, writing—original draft, J.Z.; conceptualization, methodology, supervision, funding acquisition, writing—review and editing, Y.X.; conceptualization, methodology, supervision, J.C.; supervision, project administration, X.Z.; supervision, project administration, F.Y. All the authors have read and agreed to the published version of the manuscript.

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Correspondence to Yanfeng Xing.

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Zhang, J., Xing, Y., Cao, J. et al. The gap-filling overlapping model for wire and arc additive manufacturing of multi-bead components. Int J Adv Manuf Technol 123, 737–748 (2022). https://doi.org/10.1007/s00170-022-10132-3

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