Advances in Additive Manufacturing and Joining pp 137-148 | Cite as
Energy Consumption of Welding-Based Additively Manufactured Materials
Abstract
The objective of this study is to determine a detailed energy model for Gas Metal Arc Welding (GMAW), Manual Metal Arc Welding (MMAW) processes and comparing energy consumptions of both techniques for additively manufactured rectangular blocks. Energy consumption as function of time and power calculated for Mild steel- MS-ER70, MS-E6013, stainless steel SS-ER347, SS-E308L-16, AlSi-3 ER4043 rectangular solids manufactured by welding-based additive manufacturing. Qualitatively it is known that GMAW takes less energy comparing MMAW process. However, tools and dataset to quantitatively determine energy consumption of each step of GMAW, MMAW additively manufactured materials has been missing. Energy consumption is divided for pre-processing, WAAM process, post-processing. Even each of this process demanded energy input also traced. Comparisons of both energy values with carbon foot print and considerable parameters are discussed in detail.
Keywords
Additive manufacturing Welding Wire arc additive manufacturing Energy consumptionNomenclature
- AM
Additive Manufacturing
- SLA
Stereolithography
- FDM
Fused Deposition Modeling
- EBM
Electron Beam Melting
- DMLS
Direct Metal Laser Sintering
- LENS
Laser Engineered Net Shaping
- PBF
Powder Bed Fusion
- DED
Direct Energy Deposition
- WAAM
Wire Arc Additive Manufacturing
- GTAW/TIG
Tungsten Inert Gas welding
- MMAW
Manual Metal Arc Welding
- GMAW/MIG
Gas Metal Arc Welding
- TGMAW
Tandem Gas Metal Arc Welding
- FSW
Friction Stir Welding
Notes
Acknowledgement
Author would like to thank Senior Technician Mr. Muthurajan and his team, Mr. Rajesh for their timely support during experiments at Central workshop, Indian Institute of Technology Madras.
References
- 1.Gibson, I., Rosen, D.W., Stucker, B.: Additive Manufacturing Technologies Rapid Prototyping to Direct Digital Manufacturing. Springer, New York (2010)Google Scholar
- 2.EIA: Manufacturing Energy Consumption Survey (MECS)—Analysis & Projections. U.S Energy Information Administration (EIA) (2013)Google Scholar
- 3.Bambach, M.D., Bambach, M., Sviridov, A., Weiss, S.: New process chains involving additive manufacturing and metal forming—a chance for saving energy? In: International Conference on the Technology of Plasticity, Ambridge, UK (2017)Google Scholar
- 4.Bahrami, A., Valentine, A.D., Aidun, D.: Computational analysis of the effect of the welding parameters on energy consumption in GTA welding process. Int. J. Mech. Sci. 111–119 (2015)Google Scholar
- 5.Wei, Y., Zhang, H., Jiang, Z., Hon, K.K.B.: Multi-objective optimization of arc welding parameters—the trade offs between energy and thermal efficiency. J. Cleaner Prod. (2016)Google Scholar
- 6.Bai, J.Y., Yang, C.L., Lin, S.B., Dong, B.L., Fan, C.L.: Mechanical properties of 2219-Al components produced by additive manufacturing with TIG. Int. J. Addit. Manuf. Technol. (2015)Google Scholar
- 7.Wang, J.F., Sun, Q.J., Wang, H., Liu, J.P., Feng, J.C.: Effect of location on microstructure and mechanical properties of additive layer manufactured Inconel 625 using gas tungsten arc welding. Mater. Sci. Eng. 395–405 (2016)Google Scholar
- 8.Ayarkwa, K.F., Wiiliams, S.W., Ding, J.: Assessing the effect of TIG alternating current time cycle on aluminum wire + arc additive manufacture. Addit. Manuf. 186–193 (2017)Google Scholar
- 9.Jackson, M.A., Van Asten, A., Morrow, J.D., Min, S., Pfefferkorn, F.E.: A comparison of energy consumption in wire-based and powder-based additive-subtractive manufacturing. In: 44th Proceedings of the North Americal Manufacturing (2015)Google Scholar
- 10.Lu, F., Wang, H.-P., Murphy, A.B., Carlson, B.E.: Analysis of energy flow in gas metal arc welding processes through self-consistent three dimensional process simulation. Int. J. Heat Mass Transfer, 215–223, (2014)Google Scholar
- 11.Abdallah, L., El-Shennawy, T.: Reducing carbon dioxide emissions from electricity sector using smart electric grid applications. Jurnal of Eng. 8 (2013)Google Scholar