Numerical simulation of WAAM process by a GMAW weld pool model
- 326 Downloads
Additive manufacturing (AM) is a high-productivity process which can make a near-net-shape structure. In this study, the focus is the wire-arc AM (WAAM) process. In the WAAM process, wire is the depositing material. The wire melts by an arc plasma and deposits layer by layer. To establish an advanced WAAM process, it is important to make a precise structure of the intended shape. In this study, a gas metal arc welding (GMAW) weld pool model is applied to WAAM process, and influence of the deposit condition on the shape of the deposition is numerically investigated. Firstly, influence of the interpass temperature is investigated. When cooling time is set appropriately, the deposition shape becomes higher and thinner. In addition, concerning influence of the welding direction, when the welding direction is reversed for each layer, the variance of the deposition height becomes small. These numerical results show that it is important to manage the temperature and torch motion for controlling the deposition shape. These numerical results have similar tendency with experimental results and show the GMAW weld pool model is a helpful tool to predict and control the WAAM process.
KeywordsAdditive manufacturing WAAM process Numerical simulation Weld pool model Bead formation
This research was supported by the Structural Materials for Innovation of the Cross ministerial Strategic Innovation Promotion Program (SIP) of Japan Science and Technology (JST).
- 11.J. Ding, P. Colegrove, J. Mehnen, S. Ganguly, P.M. Sequeira Almeida, F. Wangb and S. Williams, Thermo-mechanical analysis of wire and arc additive layer manufacturing process on large multi-layer parts, Computation Material Science, 50 (2011), 3315–3322Google Scholar
- 13.Zhou X, Zhang H, Wang G, Bai X (2016) Three-dimentional numerical simulation of arc and metal transport in arc welding based additive manufacturing. Int J Heat Mass Transf 103:521–537. https://doi.org/10.1016/j.ijheatmasstransfer.2016.06.084 CrossRefGoogle Scholar
- 15.Amsden AA and Harlow FH (1970) The SMAC method: a numerical technique for calculating incompressible fluid flows, Los Alamos science laboratory report, LA-4370Google Scholar
- 17.Rao ZH, Hu J, Liao SM, Tsai HL (2010) Modeling of the transport phenomena in GMAW using argon–helium mixtures. Part I—the arc. Int J Heat Mass Transf 53(25-26):5707–5721. https://doi.org/10.1016/j.ijheatmasstransfer.2010.08.009 CrossRefGoogle Scholar