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Evaluation of thermal and geometric properties of martensitic stainless steel thin walls built by additive manufacturing cold metal transfer (CMT) processes

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Abstract

Additive manufacturing is often seen as a novel alternative compared to well-consolidated, subtractive, and formative manufacturing processes. Its presence in the industrial environment is rapidly increasing, and its performance and flexibility may be the answer for present-day fabrication challenges, combining solutions to minimize environmental impacts without losing competitiveness or product quality. Arc welding-based additive manufacturing (also known as wire arc additive manufacturing, WAAM) has been gaining prominence in the current Industry 4.0 scenario. For the advancement of this technology, multiple output analysis of the pertinent welding processes is essential, especially regarding studies applied to materials such as high-strength and high-cost steels. In this paper, a study was conducted with the AISI 420 alloy and CMT variants of the GMAW process applied to additive manufacturing of thin walls, comparing them with conventional GMAW process. The welding processes and deposited welds used were analyzed on electrical, thermal, morphological, and metallurgical aspects. In the end, CMT Advanced and CMT Pulse variants stood out as opposite extremes, whereby CMT Advanced presented the best performance in relation to wall height and heat input. CMT and conventional GMAW produced good and significantly similar results, highlighting the stability of CMT.

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Availability of data and material

The raw and processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

Abbreviations

AM:

Additive manufacturing

AISI:

American Iron and Steel Institute

ASTM:

American Society for Testing and Materials

BTF:

Buy-to-fly

CG:

Coarse-grain

CMT:

Cold metal transfer

CTWD:

Contact tip to work distance

DF:

Dynamic feeding

GMAW:

Gas metal arc welding

GTAW:

Gas tungsten arc welding

HAZ:

Heat affected zone

HSLA:

High strength low alloy

HV:

Hardness Vickers

PAW:

Plasma arc welding

WAAM:

Wire and arc additive manufacturing

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Acknowledgements

The research proposed in this paper was supported by LABSOLDA — Welding and Mechatronics Institute and Federal University of Santa Catarina.

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Authors and Affiliations

  1. Mechanical Engineering Department, UFSC, LABSOLDA — Welding and Mechatronics Institute, Florianópolis, Santa Catarina, Brazil

    Daniel Galeazzi, Régis Henrique Gonçalves e Silva, Alberto Bonamigo Viviani, Pedro Rocha Jaeger & Mateus Barancelli Schwedersky

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  1. Daniel Galeazzi
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  2. Régis Henrique Gonçalves e Silva
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Contributions

DG conducted the experimental procedures and was responsible for writing the paper; RHGeS contributed to the paper structure, methodology, and did the final proofreading and writing refinement; PCJR assisted the experimental procedures and proofreading; MBS provided literature and was co-responsible for writing the paper; and ABV provided literature, methods, and experimental support.

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Correspondence to Daniel Galeazzi.

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Galeazzi, D., Silva, R.H.G.e., Viviani, A.B. et al. Evaluation of thermal and geometric properties of martensitic stainless steel thin walls built by additive manufacturing cold metal transfer (CMT) processes. Int J Adv Manuf Technol 120, 2151–2165 (2022). https://doi.org/10.1007/s00170-022-08921-x

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