Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials
2.2. Experimental Design and Setup
Water content | ≤10 ppm |
Maximum Joule power | 50 W |
Baseplate temperatures | ≤600 ℃ |
2.3. Characterization
3. Results
3.1. Single-Layer Deposition
3.2. Thin-Wall Deposition
3.3. Surface Finish
3.4. Hardness and Density
3.5. Tensile Test
3.6. Post-Processing
4. Discussion
4.1. Utilization of Joule Heating
4.2. Major Influential Factors on the Morphology of the Single-Track Parts
4.3. Optimization of Thin-Walled Part Printing Parameters
5. Conclusions
- (1)
- Introducing a Joule heating source decreases the demand for laser power, and thus reduces the total printing power and heat accumulation and increases the surface quality. The maximum optical power during actual printing measured 50 W.
- (2)
- Thin-walled parts formed by using the LJWF-DMD have aspect ratios as high as 40, uniform thickness and average deviation as low as approximately 0.017 mm. Thin-walled parts with 66° inclinations are built. No visible defects, such as pores and cracks, are observed on all the specimens.
- (3)
- Progressively adjusting the parameters can improve the surface quality of the thin-walled parts. The surface roughness (Ra) below 5 μm is far smaller than that obtained using WF-based metal AM techniques and on a par with that obtained using SLM. The horizontal tensile strength is approximately 500 MPa; the elongation at fracture is 90%; even and fine dimples are observed on the fracture surface; the hardness is approximately 170 HV and is uniformly distributed at different heights; and the density is 99.37%. The LJWF-DMD is competent with the conventional processing techniques in terms of physical properties.
- (4)
- Low surface roughness alleviates the burden of post-processing the formed parts. Using electrolyte-plasma processing can greatly reduce the specimen surface roughness, from 3.6 to 0.4 μm in ten minutes only.
- (5)
- The proposed printing technique, LJWF-DMD, is expected to be applied in cases where only low-power laser is available while the required surface quality is higher, e.g., AM in outer space.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Elements | Fe | Cr | Mn | Mo | Ni | Si | C |
---|---|---|---|---|---|---|---|
Wt% | 64.447 | 17.3 | 1.74 | 2.66 | 13.1 | 0.73 | 0.023 |
Parameter | Value |
---|---|
Laser system type | Model YLPN-WELD-DEM0-2 |
Laser type | Ytterbium fiber laser |
Laser mode | CW(continuous wave) |
Emission wave length | 1064 nm |
Laser Max power | 50 W |
Laser incidence angle | 50–80° |
Wire feeding angle | 30–60° |
Min. beam diameter | 80 μm |
Maximum moving rate | 300 mm/min |
Maximum wire feed rate | 600 mm/min |
Wire feeding direction | Front |
Wire diameter | 0.3 mm |
Shielding gas | Ar |
Oxygen content | ≤10 ppm |
(1) |
Number | 1 | 2 | 3 | 4 |
---|---|---|---|---|
upper | 0.595 | 0.589 | 0.602 | 0.604 |
lower | 0.568 | 0.573 | 0.563 | 0.557 |
K | Direction | Ra (μm) | Rz (μm) |
---|---|---|---|
1 | Horizontal | 0.7 | 4.2 |
1 | Horizontal | 0.8 | 3.9 |
1 | Horizontal | 0.7 | 3.4 |
1 | Vertical | 2.3 | 12.1 |
1 | Vertical | 2.2 | 10.8 |
1 | Vertical | 2.4 | 12.1 |
1.5 | Horizontal | 2.0 | 11.6 |
1.5 | Horizontal | 1.4 | 12.6 |
1.5 | Horizontal | 2.3 | 9.9 |
1.5 | Vertical | 3.8 | 17.9 |
1.5 | Vertical | 3.3 | 17.3 |
1.5 | Vertical | 3.8 | 18.4 |
Materials | Process | Surface Roughness | Reference |
---|---|---|---|
Powder | SLM | Sa (4–10 μm) | Imade, K. et al. (2018) [30] |
SLM | Ra (3–4 μm); Rz (16–20 μm) | Matras, A. (2020) [31] | |
EBM | Ra (18–22 μm) | Borrelli, R. et al. (2019) [17] | |
Wire | WAAM | Ra (200 μm) | Xiong, J. et al. (2017) [32] |
FW-LMD | Ra (8–16 μm) | Muhammad, O.S. et al. (2019) [22] | |
LJWF-DMD | Ra (3–5 μm); Rz (4–20 μm); Sa (4–8 μm) | This study |
Time | 0 min | 2 min | 4 min | 6 min | 8 min | 10 min |
---|---|---|---|---|---|---|
Specimens | | | | | | |
Ra (μm) | 3.6 | 2.5 | 1.3 | 0.7 | 0.5 | 0.4 |
Number | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 |
---|---|---|---|---|---|---|---|---|---|
K | 1 | 1 | 1 | 0.8 | 0.8 | 0.8 | 0.5 | 0.5 | 0.5 |
VM (mm/min) | 5 | 10 | 15 | 5 | 10 | 15 | 5 | 10 | 15 |
H (μm) | 262 | 271 | 272 | 218 | 224 | 228 | 137 | 147 | 150 |
W (μm) | 325 | 323 | 321 | 314 | 312 | 309 | 300 | 297 | 294 |
α (°) | 116 | 124 | 132 | 96 | 100 | 106 | 64 | 72 | 79 |
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Li, B.; Wang, B.; Zhu, G.; Zhang, L.; Lu, B. Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power. Materials 2021, 14, 4265. https://doi.org/10.3390/ma14154265
Li B, Wang B, Zhu G, Zhang L, Lu B. Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power. Materials. 2021; 14(15):4265. https://doi.org/10.3390/ma14154265
Chicago/Turabian StyleLi, Bobo, Bowen Wang, Greg Zhu, Lijuan Zhang, and Bingheng Lu. 2021. "Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power" Materials 14, no. 15: 4265. https://doi.org/10.3390/ma14154265