Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V
Abstract
:1. Introduction
2. Materials and Methods
3. Results and Discussion
3.1. CMT
3.2. CSC
3.3. DCEN
3.4. Microstructure
4. Conclusions
- During CMT, the burning arc at the ignition start misses the wire tip, which occurs almost in every cycle and can significantly affect the heat input distribution. Such a phenomenon can be explained by the cumulative effect of the low wire tip temperature and the refractory properties of Ti, which results in insufficient anode vaporization; the lack of anode vaporization develops in the diffusive arc burning mode until the wire tip is heated enough to produce the anode spot. The discovered effect tends to play a crucial role in arc burning stability during CMT.
- The effective wall width considerably differs between walls, printed using different transfer modes. The width efficiencies are 0.62, 0.76, and 0.56 for the CMT, CSC, and DCEN walls, respectively. The wall width efficiency is influenced by the wall waviness, which depends on the heat input distribution. Heat input distribution varies during GMAW due to arc wandering, and its effect is greater in the CMT process as a result of the extended arc length. The DCEN wall inconsistency is a consequence of the higher heat input into the anode, which in the case of DCEN is the wall. The relatively high CSC wall efficiency is the result of the low arc length and sufficient heat input, produced during the arc burning phase of the metal transfer cycle.
- There was no critical difference found in the printed walls microstructure, thus the metal transfer at the investigated intervals of the transfer parameters primarily influences the geometrical properties of the manufactured structures.
- Owing to its width efficiency and sufficient arc stability, the CSC transfer process was found to be the most suitable for thin-walled structure printing among the three studied metal transfer modes. The next study will be dedicated to further development of CSC metal transfer at higher process rates.
Supplementary Materials
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Metal Transfer Mode | Average Current, A | Average Voltage, V |
---|---|---|
CMT | 63 | 11.3 |
CSC | 127 | 15.7 |
DCEN | 174 | 15.6 |
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Panchenko, O.; Kurushkin, D.; Isupov, F.; Naumov, A.; Kladov, I.; Surenkova, M. Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V. Materials 2021, 14, 2457. https://doi.org/10.3390/ma14092457
Panchenko O, Kurushkin D, Isupov F, Naumov A, Kladov I, Surenkova M. Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V. Materials. 2021; 14(9):2457. https://doi.org/10.3390/ma14092457
Chicago/Turabian StylePanchenko, Oleg, Dmitry Kurushkin, Fedor Isupov, Anton Naumov, Ivan Kladov, and Margarita Surenkova. 2021. "Gas Metal Arc Welding Modes in Wire Arc Additive Manufacturing of Ti-6Al-4V" Materials 14, no. 9: 2457. https://doi.org/10.3390/ma14092457