Influence of process parameters and head orientation on bead geometry for coaxial wire laser additive manufacturing

Influence of process parameters and head orientation on bead geometry for coaxial wire laser additive manufacturing

ROCH Clément, TOURNIER Christophe, LAVERNHE Sylvain

download PDF

Abstract. Among Directed Energy Deposition (DED) processes for metallic materials, Wire Laser Additive Manufacturing (WLAM), distinguishes itself by the use of a laser beam to melt a metallic wire and produce beads. Successive depositions of overlapping beads generate volumes to obtain parts. Thus, controlling bead geometries is essential for the additive manufacturing process. Several research works have studied these geometries and the influence of the main manufacturing parameters on their dimensions, but few investigated the effect of feeding direction or wire angle. Moreover, all studies on wire angle were carried out with lateral feeding and a constant laser orientation. This paper focuses on the influence of the deposition head orientation for a coaxial wire feed with 3 laser beams on bead geometries. An experimental campaign is conducted with different orientations relatively to a horizontal substrate and the external profiles are measured using optical instruments in order to extract the average profiles and characteristic dimensions. Results indicate an influence of the head rotation around its axis and lateral tilt on the height, width, and asymmetry of the beads.

Keywords
Additive Manufacturing, Laser Wire, Bead Geometry

Published online 4/19/2023, 9 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: ROCH Clément, TOURNIER Christophe, LAVERNHE Sylvain, Influence of process parameters and head orientation on bead geometry for coaxial wire laser additive manufacturing, Materials Research Proceedings, Vol. 28, pp 119-127, 2023

DOI: https://doi.org/10.21741/9781644902479-14

The article was published as article 14 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] Z. Nie, G. Wang, J.D. McGuffin-Cawley, B. Narayanan, S. Zhang, D. Schwam, M. Kottman, Y. Rong, Experimental study and modeling of H13 steel deposition using laser hot-wire additive manufacturing, J. Mater. Process. Technol. 235 (2016) 171-186. https://doi.org/10.1016/j.jmatprotec.2016.04.006
[2] F. Du, J. Zhu, X. Ding, Q. Zhang, H. Ma, J. Yang, H. Cao, Z. Ling, G. Wang, X. Duan, S. Fan, Dimensional characteristics of Ti-6Al-4V thin-walled parts prepared by wire-based multi-laser additive manufacturing in vacuum, Rapid Prototyp. J. 25 (2019) 849-856. https://doi.org/10.1108/RPJ-08-2018-0207
[3] A. Ayed, G. Bras, H. Bernard, P. Michaud, Y. Balcaen, J. Alexis, Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts, MATEC Web of Conferences 321 2020. https://doi.org/10.1051/matecconf/202032103002
[4] W. Aiyiti, W. Zhao, B. Lu, Y. Tang, Investigation of the overlapping parameters of MPAW-based rapid prototyping, Rapid Prototyp. J. 12 (2006) 165-172. https://doi.org/10.1108/13552540610670744
[5] A. Sharma, N. Arora, B. Mishra, Mathematical Model of Bead Profile in High Deposition Welds, J. Mater. Process. Technol. 220 (2015) 65-75. https://doi.org/10.1016/j.jmatprotec.2015.01.009
[6] Y. Cao, S. Zhu, X. Liang, W. Wang, Overlapping model of beads and curve fitting of bead section for rapid manufacturing by robotic MAG welding process, Robot. Comput.-Integr. Manuf. 27 (2011) 641-645. https://doi.org/10.1016/j.rcim.2010.11.002
[7] G.H. Kim, S.I. Kang, S.B. Lee, Study on the estimate of weld bead shape and the compensation of welding parameters by considering weld defects in horizontal fillet welding, International Conference on Knowledge-Based Intelligent Electronic Systems, 2000, pp. 212-216. doi:10.1109/KES.1999.820157
[8] S. Suryakumar, K.P. Karunakaran, A. Bernard, U. Chandrasekhar, R. Nadella, D. Sharma, Weld bead modeling and process optimization in Hybrid Layered Manufacturing, Computer-Aided Des. 43 (2011) 331-344. https://doi.org/10.1016/j.cad.2011.01.006
[9] M. Kumar, S.S. Kumar, A. Sharma, Bi-polynomial fourth-order weld bead model for improved material utilization and accuracy in wire-arc additive manufacturing: A case of transverse twin-wire welding, Adv. Industr. Manuf. Eng. 2 (2021) 100049. https://doi.org/10.1016/j.aime.2021.100049
[10] D. Ding, Z. Pan, D. Cuiuri, H. Li, A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM), Robot. Comput.-Integr. Manuf. 31 (2015) 101-110. https://doi.org/10.1016/j.rcim.2014.08.008
[11] J. Xiong, G. Zhang, H. Gao, L. Wu, Modeling of bead section profile and overlapping beads with experimental validation for robotic GMAW-based rapid manufacturing, Robot. Comput.-Integr. Manuf. 29 (2013) 417-423. https://doi.org/10.1016/j.rcim.2012.09.011
[12] T.E. Abioye, J. Folkes, A.T. Clare, A parametric study of Inconel 625 wire laser deposition, J. Mater. Process. Technol. 213 (2013) 2145-2151. https://doi.org/10.1016/j.jmatprotec.2013.06.007
[13] A.G. Medrano-Tellez, Fiber laser metal deposition with wire: parameters study and temperature control, PhD Thesis, University of Nottingham, 2010.
[14] S.H. Mok, G. Bi, J. Folkes, I. Pashby, Deposition of Ti-6Al-4V using a high power diode laser and wire, Part I: Investigation on the process characteristics, Surf. Coat. Technol. 202 (2008) 3933-3939. https://doi.org/10.1016/j.surfcoat.2008.02.008
[15] S. Ocylok, M. Leichnitza, S. Thieme, S. Nowotny, Investigations on laser metal deposition of stainless steel 316Lwith coaxial wire feeding, 9th International Conference on Photonic Technologies (LANE 2016), 2016.