Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing
Abstract
:1. Introduction
2. Mathematical Models and Methods
2.1. Assumptions
- (1)
- The arc plasma is considered to be continuous, laminar Newton flow, and the arc plasma is in a steady state and satisfies the local thermal equilibrium (LTE) state [12].
- (2)
- Due to the constant change in the shape of the wire tip in the actual WAAM process, it is not easy to describe it by a unified body. To simplify the numerical model, the wire tip is simplified as a plane [13].
- (3)
- Since the arc is not sensitive to the electrode surface temperature, the surface of the single-pass multi-layer wall is set to 2000 K, and the wire tip is set to 3000 K [28].
- (4)
- Since the arc velocity is much greater than the metal flow velocity, the influence of the droplet transfer on the arc is ignored [28], and only the arc simulation is studied, so the steady-state calculation method is adopted.
- (5)
- To simplify the mathematical model, it is assumed that the upper surface of the single-pass multi-layer wall is a circular arc surface. The corner angle between the circular arc surface and the sidewall is fixed at 30° in this study.
2.2. Governing Equations
2.3. The Experimental System and Boundary Conditions
No. | Welding Speed (mm/s) | Shielding Gas Flow Rate (L/min) | Designed δ (mm) | Measured δ (mm) |
---|---|---|---|---|
1 | 24 | 20 | 1 | 1.4 |
2 | 22 | 20 | 2 | 1.9 |
3 | 18 | 20 | 3 | 3.1 |
4 | 10 | 20 | 4 | 4.2 |
5 | 8 | 20 | 5 | 5.1 |
6 | 4.5 | 20 | 6 | 6.2 |
7 | 3.5 | 20 | 8 | 8.1 |
8 | 2.8 | 20 | 10 | 10.2 |
9 | 2.5 | 20 | 12 | 12.2 |
10 | 2 | 20 | 14 | 14.3 |
11 | 4 | 20 | +∞ (a single bead depositing) | +∞ (a single bead depositing) |
Boundaries | (m/s) | T (K) | (V) | (Wb/m) |
---|---|---|---|---|
wire-bottom | — | 3000 | ||
wire-wall | — | coupled | coupled | |
gas-in | 300 | |||
gas-out | — | 300 | 0 | |
workpiece | — |
3. Results and Discussion
3.1. The Arc Shape and Temperature Fields
3.2. Velocity Fields
3.3. The Arc Parameters Distribution along the Characteristic Path
4. Conclusions
- (1)
- The length of the arc along the sidewall decreases with the increase in the wall thickness, and the arc shape tends to be bell-shaped. The wall thickness has little influence on the temperature, velocity, current density, and electromagnetic force distribution along the welding direction, which is similar to that of the plate welding. The coverage of shielding gas on the sidewall decreases with the increase in wall thickness. When δ is slightly less than Φ, the forming quality of the deposited wall is the best.
- (2)
- When δ < Φ, the peak temperature of the arc centre, the peak current density, and peak and valley electromagnetic force along the welding direction decrease with the increase in the wall thickness, and the increase in wall thickness will lead to the reduction in arc contraction.
- (3)
- When δ > Φ, the peak temperature of the arc centre, the peak current density, and peak and valley electromagnetic force along the welding direction increase slowly with the increase in wall thickness, and similar to the case of plate welding, the small cathode area on the top surface of the wall will lead to a weak trend of the arc contraction.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
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Zhou, C.; Zhang, X.; Peng, Y.; Huang, Y.; Wang, K.; Wang, J.; Zhou, M. Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing. Metals 2022, 12, 1563. https://doi.org/10.3390/met12101563
Zhou C, Zhang X, Peng Y, Huang Y, Wang K, Wang J, Zhou M. Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing. Metals. 2022; 12(10):1563. https://doi.org/10.3390/met12101563
Chicago/Turabian StyleZhou, Chundong, Xiaoyong Zhang, Yong Peng, Yong Huang, Kehong Wang, Jianchun Wang, and Ming Zhou. 2022. "Simulation of the Influence of the as-Deposited Wall Thickness on Arc Shape and Stability during Wire Arc Additive Manufacturing" Metals 12, no. 10: 1563. https://doi.org/10.3390/met12101563