Abstract
Wire arc additive manufacturing (WAAM) is one of the metal additive manufacturing methods in which rapid fabrication is possible for components of big size. A significant amount of heat energy is transferred to the workpiece during this process, with a defined idle period so that the workpiece cools down between each layer of deposition. This variable cooling rate technique keeps the workpiece from collapsing and crack growth by maintaining a proper inter-pass temperature. The main challenge is to choose an inter-pass ambient cooling time to mitigate the residual stresses and distortions induced in the workpiece. A numerical model is developed to study the variation of residual stress with respect to change in the cooling time of WAAM process. The material’s thermal and mechanical behaviour was instigated using finite element analysis, by introducing DFLUX SUBROUTINE within ABAQUS 6.20 SOFTWARE. The simulation results were analyzed and the optimum inter-pass cooling time obtained was 800 sec.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Lockett H, Ding J, Williams S, Martina F (2017) Design for wire +arc additive manufacture: design rules and build orientation selection. J Eng Des 4828(August):1–31
Adebayo A (2013) Characterization of integrated WAAM and machining processes. Cranfield University
Ding D (2015) Process planning for robotic wire and arc additive manufacturing. University of Wollogong
Ding D, Pan Z, Cuiuri D, Li H (2014) A tool-path generation strategy for wire and arc additive manufacturing. Int J Adv Manuf Technol
Wu B, Ding D, Pan Z, Cuiuri D, Li H, Han J, Fei Z (2017) Effects of heat accumulation on the arc characteristics and metal transfer behavior in wire arc additive manufacturing of Ti6Al4V. J Mater Process Technol 250:304–312
Antonysamy AA (2012) Microstructure, texture and mechanical property evolution during additive manufacturing of Ti6Al4V alloy for aerospace applications
Reisgen U, Sharma R, Mann S, Oster L (2020) Increasing the manufacturing efficiency of WAAM by advanced cooling strategies
Poquillon D, Armand C, Huez J (2013) Oxidation and oxygen diffusion in Ti–6al–4V alloy: improving measurements during sims analysis by rotating the sample. pp 249–259
McAndrew AR et al (2018) Inter-pass rolling of Ti-6Al-4V wire +arc additively manufactured features for microstructural refinement. Addit Manuf 21(March):340–349
Rodriguez N, Vázquez L, Huarte I, Arruti E, Tabernero I, Alvarez P (2018) Wire and arc additive manufacturing: a comparison between CMT and Top TIG processes applied to stainless steel. Weld World 62:1083–1096
Bermingham MJ, Nicastro L, Kent D, Chen Y, Dargusch MS (2018) Optimizing the mechanical properties of Ti-6Al-4V components produced by wire + arc additive manufacturing with post process heat treatments. J Alloys Compd 753:247–255
Goldak J, Chakravarti A, Bibby M (1984) A new finite element model for welding heat sources. Metall Trans B 15(2):299–305
Tangestani R, Farrahi GH, Shishegar M, Aghchehkandi BP, Ganguly S, Mehmanparast A (2020) Effects of vertical and pinch rolling on residual stress distributions in wire and arc additively manufactured components. J Mater Eng Perform 1-12
Jin W, Zhang C, Jin S, Tian Y, Wellmann D, Liu W (2020) Wire arc additive manufacturing of stainless steels: a review. Appl Sci 10(5):1563
Montevecchi F, Venturini G, Scippa A, Campatelli G (2016) Finite element modelling of wire-arc-additive-manufacturing process. Proc CIRP, 109–114
Ding J (2012) Thermo-mechanical analysis of wire and arc additive manufacturing processes. Cranfield University Library, Bedford
Goldak J, Bibby M, Moore J, House R, Patel B (1986) Computer modeling of heat flow in welds. Metall Trans B 17:587–600
Acknowledgements
The authors would like to thank the Sophisticated Instrumentation Centre and all the Research Scholars of Mechatronics and Instrumentation lab of IIT Indore for their support and suggestions in this work.
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2022 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
About this paper
Cite this paper
Kumar, G.T.A.T. et al. (2022). Theoretical Investigations on Influence of Inter-pass Cooling Conditions on Wire Arc Additive Manufactured Parts. In: Palani, I.A., Sathiya, P., Palanisamy, D. (eds) Recent Advances in Materials and Modern Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-19-0244-4_62
Download citation
DOI: https://doi.org/10.1007/978-981-19-0244-4_62
Published:
Publisher Name: Springer, Singapore
Print ISBN: 978-981-19-0243-7
Online ISBN: 978-981-19-0244-4
eBook Packages: EngineeringEngineering (R0)