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Deposition geometrical characteristics of wire arc additive-manufactured AA2219 aluminium alloy with cold metal transfer pulse advance arc mode

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Abstract

A cold metal transfer pulse advance (CMT-PA) arc mode was employed in this paper for the wire arc additive manufacturing of Al alloy. The effects of process parameters on deposition surface morphologies and geometrical characteristics were investigated. And a deposition width model was built by the multiple linear regressions. Based on the principle that the volume of the sample is equal to that of filler wire, a deposition height model was simultaneously derived. The results indicate that the disparity between two trends of droplet spreading in horizontal and molten pool tangential direction determines directly the final deposition geometrical characteristics. And two trends would be mainly affected by the heat input and arc force closely related to process parameters. The influences of three factors on the effective width percentage show a trend of first increasing and then decreasing. So, it provides an optimal process window for good deposition forming. The effective width percentage reaches 83% and the machining allowance is only 0.71 mm, which significantly improves material utilization and reduces manufacturing costs. Besides, the error rates of deposition width and height models are less than 4% and 6%, respectively. Two models can facilitate fabricating different size complex parts and make a profit for the actual production.

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Funding

This research is financially supported by the National Natural Science Foundation of China (grant nos. 51775206) and the foundation of the National Key Laboratory for Remanufacturing (No. 6142005200401).

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Authors and Affiliations

  1. Wuhan National Laboratory for Optoelectronics (WNLO), Huazhong University of Science and Technology, 430074, Wuhan, People’s Republic of China

    Yazhou Zhang, Ming Gao & Yang Lu

  2. National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing, 100072, People’s Republic of China

    Wenbo Du

Authors
  1. Yazhou Zhang
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  2. Ming Gao
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  4. Wenbo Du
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Contributions

Yazhou Zhang designed and conducted the experiments, organized all the data, and wrote the manuscript. Ming Gao evaluated the obtained data and supervised all research. Yang Lu and Wenbo Du completed the auxiliary data analysis work. All authors read and approved the final manuscript.

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Correspondence to Ming Gao.

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Highlights

• The influential mechanisms of process parameters on the deposition geometrical characteristics are analyzed. Process parameters can affect the trends of droplet spreading in the horizontal direction and molten pool tangential direction. The disparity between the two trends determines the final deposition morphology.

• This paper studies the influence of process parameters on the effective width percentage and provides a process window of good deposition forming, which can improve materials utilization and reduce manufacturing costs.

• Effective deposition width and height models are established for the convenience of manufacturing different size parts in the actual production.

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Zhang, Y., Gao, M., Lu, Y. et al. Deposition geometrical characteristics of wire arc additive-manufactured AA2219 aluminium alloy with cold metal transfer pulse advance arc mode. Int J Adv Manuf Technol 123, 3807–3818 (2022). https://doi.org/10.1007/s00170-022-10460-4

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  • DOI: https://doi.org/10.1007/s00170-022-10460-4

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