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Open AccessArticle

Research on Mechanisms and Controlling Methods of Macro Defects in TC4 Alloy Fabricated by Wire Additive Manufacturing

1
School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China
2
Institute of Advanced Structure Technology, Beijing Institute of Technology, Beijing 100081, China
*
Author to whom correspondence should be addressed.
Materials 2018, 11(7), 1104; https://doi.org/10.3390/ma11071104
Received: 24 May 2018 / Revised: 9 June 2018 / Accepted: 26 June 2018 / Published: 28 June 2018
(This article belongs to the Special Issue Additive Manufacturing: Alloy Design and Process Innovations)
Wire feeding additive manufacturing (WFAM) has broad application prospects because of its advantages of low cost and high efficiency. However, with the mode of lateral wire feeding, including wire and laser additive manufacturing, gas tungsten arc additive manufacturing etc., it is easy to generate macro defects on the surface of the components because of the anisotropy of melted wire, which limits the promotion and application of WFAM. In this work, gas tungsten arc additive manufacturing with lateral wire feeding is proposed to investigate the mechanisms of macro defects. The results illustrate that the defect forms mainly include side spatters, collapse, poor flatness, and unmelted wire. It was found that the heat input, layer thickness, tool path, and wire curvature can have an impact on the macro defects. Side spatters are the most serious defects, mainly because the droplets cannot be transferred to the center of the molten pool in the lateral wire feeding mode. This research indicates that the macro defects can be controlled by optimizing the process parameters. Finally, block parts without macro defects were fabricated, which is meaningful for the further application of WFAM. View Full-Text
Keywords: wire feeding additive manufacturing; wire lateral feeding; macro defects; side spatters wire feeding additive manufacturing; wire lateral feeding; macro defects; side spatters
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MDPI and ACS Style

Ji, L.; Lu, J.; Tang, S.; Wu, Q.; Wang, J.; Ma, S.; Fan, H.; Liu, C. Research on Mechanisms and Controlling Methods of Macro Defects in TC4 Alloy Fabricated by Wire Additive Manufacturing. Materials 2018, 11, 1104.

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