Numerical analysis on the effect of process parameters on deposition geometry in wire arc additive manufacturing

Shilong FAN; Fei YANG; Xiaonan ZHU; Zhaowei DIAO; Lin CHEN; Mingzhe RONG

doi:10.1088/2058-6272/ac4f41

Plasma Science and Technology > 2022 > 24(4): 044001. > DOI: 10.1088/2058-6272/ac4f41

Shilong FAN, Fei YANG, Xiaonan ZHU, Zhaowei DIAO, Lin CHEN, Mingzhe RONG. Numerical analysis on the effect of process parameters on deposition geometry in wire arc additive manufacturing[J]. Plasma Science and Technology, 2022, 24(4): 044001. DOI: 10.1088/2058-6272/ac4f41

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Numerical analysis on the effect of process parameters on deposition geometry in wire arc additive manufacturing

State Key Laboratory of Electrical Insulation and Power Equipment, School of Electrical Engineering, Xi'an Jiaotong University, Xi'an 710049, People's Republic of China

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Corresponding author:
Fei YANG,E-mail: yfei2007@mail.xjtu.edu.cn

Mingzhe RONG,E-mail: mzrong@mail.xjtu.edu.cn
Received Date: September 10, 2021
Revised Date: January 16, 2022
Accepted Date: January 25, 2022
Available Online: December 15, 2023
Published Date: April 10, 2022

Graphical Abstract

Abstract

Abstract

Here we develop a two-dimensional numerical model of wire and arc additive manufacturing (WAAM) to determine the relationship between process parameters and deposition geometry, and to reveal the influence mechanism of process parameters on deposition geometry. From the predictive results, a higher wire feed rate matched with a higher current could generate a larger and hotter droplet, and thus transfer more thermal and kinetic energy into melt pool, which results in a wider and lower deposited layer with deeper penetration. Moreover, a higher preheat temperature could enlarge melt pool volume and thus enhance heat and mass convection along both axial and radial directions, which gives rise to a wider and higher deposited layer with deeper penetration. These findings offer theoretical guidelines for the acquirement of acceptable deposition shape and optimal deposition quality through adjusting process parameters in fabricating WAAM components.
- additive manufacturing,
- arc plasma,
- process parameter,
- deposition geometry,
- numerical analysis

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Acknowledgments

This work was supported by National Natural Science Foundation of China (Nos. 52077172, U1966602), Shaanxi Province 'Sanqin scholar-s' Innovation Team Project (Key technology of advanced DC power equipment and its industrialization demonstration innovation team of Xi'an Jiaotong University).

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Numerical analysis on the effect of process parameters on deposition geometry in wire arc additive manufacturing

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