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Structural element shaping on a plate in the manufacture of a hybrid product from aluminum alloy using WAAM technology

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Abstract

For the wire and arc additive manufacturing (WAAM) process, the results of studies of the geometry shaping of the deposited preform elements on 5086 aluminum alloy plates and developing a set of WAAM technology design procedures are presented. Studies during the surfacing of the first bead on the plate were carried out under the conditions of the established mode of non-pulse jet transfer at reverse polarity and various surfacing rates. Correlation interactions are studied, and mathematical dependences are obtained to describe the relationship between the process parameters and the bead geometry. It is shown that the geometric parameters will change along the length of the bead and, moreover, depending on the deposition rate, which must be taken into account when designing the WAAM process. For an element of the “cooling fin wall with variable height section” type in the manufacture of a preform, the correlation relationships of the geometry and process parameters were studied under the conditions of the actual layer-by-layer variable surfacing mode, the sensitivity of the output parameters to the process parameters was studied, the sensitivity coefficients were determined, and mathematical models were constructed for predicting and deviating the output parameters from the deviations of the input ones. The article shows and substantiates the compensatory nature of the effect of changing the magnitude of the current and speed on the geometric parameters of the beads, which can be used in the design and control of the WAAM process. For the main design tasks, a number of exploratory design procedures for WAAM are proposed that best organize the design process, as well as their formalized rules based on mathematical models. The rules for choosing the initial setting point for the process of direct supply of energy and material are considered, taking into account changes in the geometry of the beads along their length.

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Acknowledgements

Use of equipment of Krasnoyarsk Regional Center of Research Equipment of Federal Research Center «Krasnoyarsk Science Center SB RAS» is acknowledged.

Funding

The research was carried out within the framework of the state assignment of the Ministry of Science and Higher Education of the Russian Federation (scientific theme code FSRZ-2020–0011).

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  1. Siberian Federal University, Krasnoyarsk, 660025, Krasnoyarsk Region, Russian Federation

    Nikolay Nikolaevich Dovzhenko, Aleksandr Igorevich Demchenko, Andrey Alekseevich Bezrukikh, Kirill Sergeevich Zhuchenko, Ivan Nikolaevich Dovzhenko, Denis Sergeevich Voroshilov & Irina Sergeevna Dementeva

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  1. Nikolay Nikolaevich Dovzhenko
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Dovzhenko, N.N., Demchenko, A.I., Bezrukikh, A.A. et al. Structural element shaping on a plate in the manufacture of a hybrid product from aluminum alloy using WAAM technology. Int J Adv Manuf Technol 123, 3183–3204 (2022). https://doi.org/10.1007/s00170-022-10310-3

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