Skip to main content
SpringerLink
Log in

Numerical simulation of thermal processes in cold metal transfer-based additive manufacturing

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Wire arc additive manufacturing (WAAM) based on cold metal transfer (CMT) technology is very suitable for additive manufacturing of light metals such as aluminum and magnesium alloys due to its low heat input. The temperature field in CMT additive manufacturing determines the microstructure evolution and mechanical properties. However, the mechanism of CMT-related process parameters affecting the thermal process and molten pool geometry in additive manufacturing is still unclear. The finite element analysis model of the CMT additive manufacturing process was established based on element birth and death technology, and the temperature field and molten pool shape in the CMT additive manufacturing process were quantitatively studied. The results show that with the increase in welding speed, the maximum temperature of the molten pool decreases, the length of the molten pool decreases, and the depth of the molten pool changes little. The effect of interlayer cooling on the temperature field of CMT additive manufacturing was quantitatively analyzed. The study found that without cooling between the deposited layers, heat accumulation will occur in the component of additive manufacturing, and the peak temperature will be higher. With the increase of the additive manufacturing layer number, the peak temperature of the additive manufacturing layer increases. With the increase of additive layer number and no cooling between sedimentary layers, the length of the molten pool increases obviously. The correctness of the model is verified by the experimental measurement of weld geometry in CMT additive manufacturing of AA5356 aluminum alloy. This study provides a theoretical basis for the optimization of the CMT additive manufacturing process of aluminum alloy.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

References

  1. DebRoy T, Wei HL, Zuback JS, Mukherjee T, Elmer JW, Milewski JO, Beese AM, Wilson-Heid A, De A, Zhang W (2018) Additive manufacturing of metallic components – Process, structure and properties. Prog Mater Sci 92:112–224. https://doi.org/10.1016/j.pmatsci.2017.10.001

    Article  Google Scholar 

  2. Herzog D, Seyda V, Wycisk E, Emmelmann C (2016) Additive manufacturing of metals. Acta Mater 117:371–392. https://doi.org/10.1016/j.actamat.2016.07.019

    Article  Google Scholar 

  3. Körner C (2016) Additive manufacturing of metallic components by selective electron beam melting - a review. Int Mater Rev 61(5):361–377. https://doi.org/10.1080/09506608.2016.1176289

    Article  Google Scholar 

  4. Yap CY, Chua CK, Dong ZL, Liu ZH, Zhang DQ, Loh LE, Sing SL (2015) Review of selective laser melting: Materials and applications. Appl Phys Rev 2(4). https://doi.org/10.1063/1.4935926

  5. Gu DD, Meiners W, Wissenbach K, Poprawe R (2012) Laser additive manufacturing of metallic components: materials, processes and mechanisms. Int Mater Rev 57(3):133–164. https://doi.org/10.1179/1743280411Y.0000000014

    Article  Google Scholar 

  6. Cunningham CR, Flynn JM, Shokrani A, Dhokia V, Newman ST (2018) Invited review article: Strategies and processes for high quality wire arc additive manufacturing. Addit Manuf 22:672–686. https://doi.org/10.1016/j.addma.2018.06.020

    Article  Google Scholar 

  7. Xia C, Pan Z, Polden J, Li H, Xu Y, Chen S, Zhang Y (2020) A review on wire arc additive manufacturing: Monitoring, control and a framework of automated system. J Manuf Syst 57:31–45. https://doi.org/10.1016/j.jmsy.2020.08.008

    Article  Google Scholar 

  8. Verma J, Padap AK (2023) Evolution of microstructure and mechanical characteristics of friction stir welded ultrafine-grained aluminum alloy 6082. Materialwiss Werkst 54(8):1003–1013. https://doi.org/10.1002/mawe.202300034

    Article  Google Scholar 

  9. Pattanayak S, Sahoo SK (2021) Gas metal arc welding based additive manufacturing—a review. Cirp J Manuf Sci Tec 33:398–442. https://doi.org/10.1016/j.cirpj.2021.04.010

    Article  Google Scholar 

  10. Wu B, Pan Z, Ding D, Cuiuri D, Li H, Xu J, Norrish J (2018) A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement. J Manuf Process 35:127–139. https://doi.org/10.1016/j.jmapro.2018.08.001

    Article  Google Scholar 

  11. Selvi S, Vishvaksenan A, Rajasekar E (2018) Cold metal transfer (CMT) technology - An overview. Defence Technol 14(1):28–44. https://doi.org/10.1016/j.dt.2017.08.002

    Article  Google Scholar 

  12. Priarone PC, Catalano AR, Simeone A, Settineri L (2022) Effects of deposition parameters on cumulative energy demand for Cold Metal Transfer additive manufacturing processes. Cirp Ann 71(1):17–20. https://doi.org/10.1016/j.cirp.2022.03.022

    Article  Google Scholar 

  13. Liu Z, Zhang P, Li S, Wu D, Yu Z (2020) Wire and arc additive manufacturing of 4043 Al alloy using a cold metal transfer method. Int J Miner Metall Mater 27(6):783–791. https://doi.org/10.1007/s12613-019-1930-6

    Article  Google Scholar 

  14. Wang S, Gu H, Wang W, Li C, Ren L, Wang Z, Zhai Y, Ma P (2020) The influence of heat input on the microstructure and properties of wire-arc-additive-manufactured al-cu-sn alloy deposits. Metals-Basel 10(1):79. https://doi.org/10.3390/met10010079

    Article  Google Scholar 

  15. Azar AS (2015) A heat source model for cold metal transfer (CMT) welding. J Therm Anal Calorim 122(2):741–746. https://doi.org/10.1007/s10973-015-4809-4

    Article  Google Scholar 

  16. Zapico EP, Lutey AHA, Ascari A, Gómez Pérez CR, Liverani E, Fortunato A (2018) An improved model for cold metal transfer welding of aluminium alloys. J Therm Anal Calorim 131(3):3003–3009. https://doi.org/10.1007/s10973-017-6800-8

    Article  Google Scholar 

  17. Anca A, Fachinotti VD, Escobar-Palafox G, Cardona A (2011) Computational modelling of shaped metal deposition. Int J Numer Meth Eng 85(1):84–106. https://doi.org/10.1002/nme.2959

    Article  Google Scholar 

  18. Sharma GK, Pant P, Jain PK, Kankar PK, Tandon P (2021) Numerical and experimental analysis of heat transfer in inductive conduction based wire metal deposition process. Proc Inst Mech Eng C J Mech Eng Sci 236(5):2395–2407. https://doi.org/10.1177/09544062211028267

    Article  Google Scholar 

  19. Ding D, Zhang S, Lu Q, Pan Z, Li H, Wang K (2021) The well-distributed volumetric heat source model for numerical simulation of wire arc additive manufacturing process. Mater Today Commun 27:102430. https://doi.org/10.1016/j.mtcomm.2021.102430

    Article  Google Scholar 

  20. Zina N, Zahaf S, Bouaziz SA, Brahami A, Kaid M, Chetti B, NajafiVafa Z (2019) Numerical simulation on the effect of friction stir welding parameters on the peak temperature, von mises stress, and residual stresses of 6061–t6 aluminum alloy. J Fail Anal Prev 19(6):1698–1719. https://doi.org/10.1007/s11668-019-00766-z

    Article  Google Scholar 

  21. Ericsson M (2003) Influence of welding speed on the fatigue of friction stir welds, and comparison with MIG and TIG. Int J Fatigue 25(12):1379–1387. https://doi.org/10.1016/S0142-1123(03)00059-8

    Article  Google Scholar 

  22. Cho H, Hong S, Roh J, Choi H, Kang SH, Steel RJ, Han HN (2013) Three-dimensional numerical and experimental investigation on friction stir welding processes of ferritic stainless steel. Acta Mater 61(7):2649–2661. https://doi.org/10.1016/j.actamat.2013.01.045

    Article  Google Scholar 

Download references

Acknowledgements

This work was supported by the National Key Research and Development Program of China (2022YFB4600902), the Key Research and Development Program of Shandong Province (Grant No. 2021ZLGX01) and the State Key Lab of Advanced Welding and Joining at Harbin Institute of Technology (Grant No. AWJ-21M16).

Funding

National Key Research and Development Program of China,2022YFB4600902,Lei Shi,Key Research and Development Program of Shandong Province,2021ZLGX01,Yuanning Jiang,State Key Lab of Advanced Welding and Joining at Harbin Institute of Technology,AWJ-21M16,Lei Shi

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University, Jinan, 250061, People’s Republic of China

    Long Li

  2. MOE Key Lab for Liquid-Solid Structure Evolution and Materials Processing, Shandong University, Jinan, 250061, People’s Republic of China

    Yuanning Jiang, Yichen Xiao, Haoran Chen & Lei Shi

  3. Shandong University-Weihai Research Institute of Industrial Technology, Weihai, 264209, People’s Republic of China

    Lei Shi

Authors
  1. Long Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuanning Jiang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Yichen Xiao
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Haoran Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Lei Shi
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Long Li: Investigation, Software, Visualization, Data curation, Formal analysis, Writing-original draft. Yuanning Jiang: Investigation, Validation, Formal analysis, Writing-review & editing. Yichen Xiao: Investigation, Visualization, Data curation, Writing-review & editing. Haoran Chen: Investigation, Visualization, Data curation, Writing-review & editing. Lei Shi: Validation, Formal analysis. Funding acquisition, Resources, Writing-review & editing.

Corresponding author

Correspondence to Yuanning Jiang.

Ethics declarations

Competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Li, L., Jiang, Y., Xiao, Y. et al. Numerical simulation of thermal processes in cold metal transfer-based additive manufacturing. Int J Adv Manuf Technol 130, 4431–4442 (2024). https://doi.org/10.1007/s00170-024-13019-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-024-13019-7

Keywords

Search

Navigation