Abnormal melt pool behavior in overhead wire arc-based directed energy deposition

IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
Hongbo Liu, Hui Chen, Jun Xiong
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Abstract

Overhead wire arc-based directed energy deposition (WADED) is a key technique for the in-situ fabrication of overhanging components. However, humping and dripping frequently occur during overhead WADED since gravity acting on the melt pool may make it detach from previous layers. This study investigates gravity-induced humping and dripping phenomena in overhead WADED of thin-walled low-carbon steel parts. The droplet transfer behavior of four gas metal arc (GMA) variants, i.e., continuous current GMA (CC-GMA), cold metal transfer (CMT), pulsed GMA (P-GMA), and CMT plus pulse (CMT + P), is comparatively analyzed during overhead deposition. Among the four variants, CMT + P can produce the best forming quality due to its highly stable droplet transfer. The melt pool geometry ratio D, defined as the product of melt pool length and height divided by the square of melt pool width, is proposed as an index to evaluate the probability of humping and dripping defects. A process window for overhead WADED using the CMT + P process is established. The effects of travel speed (TS), wire feed speed (WFS), and a constant WFS/TS ratio on the melt pool behavior during overhead deposition are explored. When D is below 2.0, stable melt pools and defect-free surfaces are produced. When D is greater than or equal to 2.0 but <3.9, humping is more likely to form with increasing TS or WFS. Dripping occurs when D is greater than or equal to 3.9, especially at lower TS or higher WFS. When the WFS/TS ratio is kept constant, humping and dripping defects occur more easily as WFS and the corresponding TS increase. This study lays a solid foundation for defect-free overhead WADED of complex overhanging structures.
高架线电弧定向能沉积中的异常熔池行为
架空导线电弧定向能沉积(WADED)是悬垂构件原位制造的一项关键技术。然而,由于重力作用于熔池可能使其与前几层分离,因此在架空涉水期间经常发生驼峰和滴水。本文研究了低碳钢薄壁件在重力作用下的俯仰和滴水现象。对比分析了连续电流金属电弧(CC-GMA)、冷金属电弧(CMT)、脉冲金属电弧(P-GMA)和CMT +脉冲金属电弧(CMT + P)四种气体金属电弧(GMA)在架空沉积过程中的传递行为。在四种变体中,CMT + P由于其高度稳定的液滴转移,可以产生最好的成形质量。提出了熔池几何比D,即熔池长度和高度的乘积除以熔池宽度的平方,作为评价熔池驼峰和滴水缺陷概率的指标。建立了一个使用CMT + P过程进行开销处理的过程窗口。探讨了运动速度(TS)、送丝速度(WFS)和恒定的WFS/TS比对高架沉积过程中熔池行为的影响。当D小于2.0时,熔池稳定,表面无缺陷。当D大于等于2.0,但<;3.9时,随着TS或WFS的增加,更容易形成驼峰。当D大于或等于3.9时发生滴落,特别是在TS较低或WFS较高时。当WFS/TS比一定时,随着WFS和相应TS的增加,更容易出现驼峰和滴水缺陷。本研究为复杂悬垂结构的无缺陷架空施工奠定了坚实的基础。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Journal of Manufacturing Processes
Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-
CiteScore
10.20
自引率
11.30%
发文量
833
审稿时长
50 days
期刊介绍: The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.
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