Prediction of the microstructure morphology after the WAAM process based on the FEM simulation results
SZYNDLER Joanna, APEL Markus, HÄRTEL Sebastian
download PDFAbstract. To improve understanding of the material behavior of additive-produced components, this paper focuses on the development of a numerical model that reproduces a Wire Arc Additive Manufacturing (WAAM) process, with particular attention given to the evolution of the microstructure. In this study, a finite element model in Simufact Welding software is developed, that replicates a real wire arc welding process of building a multilayer straight wall. Microscopy analysis of the weld wall cut in the middle of its length gave information about the expected microstructure morphology at different levels of the build wall. The whole experimental setup is reproduced in the software Simufact Welding. Simulation results in the form of temperature-time and temperature gradient-time history are then used as superimposed thermal conditions to simulate the microstructure evolution at different areas of the welded part by using MICRESS software.
Keywords
Finite Element Method (FEM), Wire Arc Additive Manufacturing (WAAM), Microstructure Prediction, Phase Field Method
Published online 4/24/2024, 10 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: SZYNDLER Joanna, APEL Markus, HÄRTEL Sebastian, Prediction of the microstructure morphology after the WAAM process based on the FEM simulation results, Materials Research Proceedings, Vol. 41, pp 22-31, 2024
DOI: https://doi.org/10.21741/9781644903131-3
The article was published as article 3 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] V. Madhavadas, D. Srivastava, U. Chadha, S.A. Raj, M.T.H. Sultan, F.S. Shahar, A.U.M. Shah, A review on metal additive manufacturing for intricately shaped aerospace components, CIRP Journal of Manufacturing Science and Technology, 39 (2022) 18-36. https://doi.org/10.1016/j.cirpj.2022.07.005
[2] J. Ye, P. Kyvelou, F. Gilardi, H. Lu, M. Gilbert, L. Gardner, An end-to-end framework for the additive manufacture of optimized tubular structures, IEEE Access, 9 (2021) 165476-165489. https://doi.org/10.1109/ACCESS.2021.3132797
[3] X. Zuo, W. Zhang, Y. Chen, J.P. Oliveira, Z. Zeng, Y. Li, Z. Luo, S. Ao, Wire-based directed energy deposition of NiTiTa shape memory alloys: Microstructure, phase transformation, electrochemistry, X-ray visibility and mechanical properties, Additive Manufacturing, 59 (2022) 103115. https://doi.org/10.1016/j.addma.2022.103115
[4] M. Vishnukumar, R. Pramod, A.R. Kannan, Wire arc additive manufacturing for repairing aluminium structures in marine applications, Materials Letters, 299 (2021) 130112. https://doi.org/10.1016/j.matlet.2021.130112
[5] T. Feucht, J. Lange, B. Waldschmitt, A.K. Schudlich, M. Klein, M. Oechsner, Welding process for the additive manufacturing of cantilevered components with the WAAM, Advanced Joining Processes, 125 (2020) 67-78. https://doi.org/10.1007/978-981-15-2957-3_5
[6] S. Zhou, J. Zhang, G. Yang, Y. Wang, B. Li, D. An, J. Zheng, W. Wei, Microstructure evolution and fracture behavior of Ti–6Al–4V fabricated by WAAM-LDM additive manufacturing, Journal of Materials Research and Technology, 28 (2024) 347-362. https://doi.org/10.1016/j.jmrt.2023.11.255
[7] C. Sasikumar, R. Oyyaravelu, Mechanical properties and microstructure of SS 316 L created by WAAM based on GMAW, Materials Today Communications, 38 (2024) 107807. https://doi.org/10.1016/j.mtcomm.2023.107807
[8] V. Laghi, N. Babovic, E. Benvenuti, H. Kloft, Blended structural optimization of steel joints for Wire-and-Arc Additive Manufacturing, Engineering Structures, 300 (2024) 117141. https://doi.org/10.1016/j.engstruct.2023.117141
[9] P. Kyvelou, C. Huang, J. Li, L. Gardner, Residual stresses in steel I-sections strengthened by wire arc additive manufacturing, Structures, 60 (2024) 105828. https://doi.org/10.1016/j.istruc.2023.105828
[10] A.Staroselsky, D. Voytovych, R. Acharya, Prediction of Ni-based alloy microstructure in wire arc additive manufacturing from cellular automata model, Computational Materials Science, 233 (2024) 112721. https://doi.org/10.1016/j.commatsci.2023.112721
[11] H. Mu, F. He, L. Yuan, H. Hatamian, P. Commins, Z. Pan, Online Distortion Simulation Using Generative Machine Learning Models: A Step Toward Digital Twin of Metallic Additive Manufacturing, Journal of Industrial Information Integration, (2024) 100563. https://doi.org/10.1016/j.jii.2024.100563
[12] S.I. Evans, J. Wang, J. Qin, Y. He, P. Shepherd, J. Ding, A review of WAAM for steel construction – Manufacturing, material and geometric properties, design, and future directions, Structures, 44 (2022) 1506-1522. https://doi.org/10.1016/j.istruc.2022.08.084
[13] S. Singh, S.K. Sharma, D.W. Rathod, A review on process planning strategies and challenges of WAAM, Materials Today: Proceedings, 47, 19 (2021) 6564-6575. https://doi.org/10.1016/j.matpr.2021.02.632
[14] A.S. Azar, S.K. As, O.M. Akselsen, Determination of welding heat source parameters from actual bead shape, Computational Material Science, 54 (2012) 176-182. https://doi.org/10.1016/j.commatsci.2011.10.025
[15] X. Zhou, H. Zhang, G. Wang, X. Bai, Three-dimensional numerical simulation of arc and metal transport in arc welding based additive manufacturing, International Journal of Heat and Mass Transfer, 103 (2016) 521-537. https://doi.org/10.1016/j.ijheatmasstransfer.2016.06.084
[16] Z. Hu, X. Qin, T. Shao, Welding thermal simulation and metallurgical characteristics analysis in WAAM for 5CrNiMo hot forging die remanufacturing, Procedia Engineering, 207 (2017) 2203-2208. https://doi.org/10.1016/j.proeng.2017.10.982
[17] C.T.J. Panicker, K.R. Surya, V. Senthilkumar, Novel process parameter-based approach for reducing residual stresses in WAAM, Materials Today: Proceedings, 59 (2022) 1119-1126. https://doi.org/10.1016/j.matpr.2022.03.025
[18] N.P. Gokhale, P. Kala, Thermal analysis of TIG-WAAM based metal deposition process using finite element method, Materials Today: Proceedings, 44 (2021) 453-459. https://doi.org/10.1016/j.matpr.2020.09.756
[19] Y. Ling, J. Ni, J. Antonissen, H.B. Hamouda, J.V. Voorde, M.A. Wahab, Numerical prediction of microstructure and hardness for low carbon steel wire Arc additive manufacturing components, Simulation Modelling Practice and Theory, 122 (2023) 102664. https://doi.org/10.1016/j.simpat.2022.102664
[20] V. Gornyakov, Y. Sun, J. Ding, S. Williams, Modelling and optimizing hybrid process of wire arc additive manufacturing and high-pressure rolling, 223 (2022) 111121. https://doi.org/10.1016/j.matdes.2022.111121
[21] S. Bose, A. Biswas, Y. Tiwari, M. Mukherjee, S.S. Roy, Artificial neural Network-based approaches for Bi-directional modelling of robotic wire arc additive manufacturing, Materials Today: Proceedings, 62, 12 (2022) 6507-6513. https://doi.org/10.1016/j.matpr.2022.04.331
[22] Y. Wang, X. Xu, Z. Zhao, W. Deng, J. Han, L. Bai, X. Liang, J. Yao, Coordinated monitoring and control method of deposited layer width and reinforcement in WAAM process, Journal of Manufacturing Process, 71 (2021) 306-316. https://doi.org/10.1016/j.jmapro.2021.09.033
[23] W.C. Ke, J.P. Oliveira, B.Q. Cong, S.S. Ao, Z.W. Qi, B. Peng, Z. Zeng, Multi-layer deposition mechanism in ultra high-frequency pulsed wire arc additive manufacturing (WAAM) of NiTi shape memory alloys, Additive Manufacturing, 50 (2022) 102513. https://doi.org/10.1016/j.addma.2021.102513
[24] C. Chen, H. He, J. Zhou, G. Lian, X. Huang, M. Feng, A profile transformation based recursive multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM), Journal of Manufacturing Processes, 84 (2022) 886-901. https://doi.org/10.1016/j.jmapro.2022.10.042
[25] J. Szyndler, A. Schmidt, S. Härtel, Determination of welding heat source parameters for FEM simulation based on temperature history and real bead shape. Materials Research Proceedings 28 (2023) 159-168. https://doi.org/10.21741/9781644902479-18
[26] ISO 643:2019 – Steels — Micrographic determination of the apparent grain size
[27] M. Hojny, M. Glowacki, Numerical Modelling of Steel Deformation at Extra-High Temperatures, in P. Miidla (ed.), Numerical Modelling, IntechOpen, London, 2012, 10.5772/36562. https://doi.org/10.5772/36562
[28] A. Martinovs, S. Polukoshko, E. Zaicevs, R. Revalds, Laser Hardening Process Optimizations Using FEM, Engineering for Rural Development, 2020. https://doi.org/10.22616/ERDev.2020.19.TF372
[29] J. Goldak, A.P. Chakravarti, M. Bibby, A new finite element model for welding heat sources, Metallurgical Transactions B, 15 (1984) 299-305. https://doi.org/10.1007/BF02667333
[30] Computational Materials Engineering – Thermo-Calc Software (thermocalc.com)
[31] MICRESS 7.1: http://www.micress.de.
[32] B. Böttger, M. Apel, M. Budnitzki, J. Eiken, G. Laschet, B. Zhou, Calphad coupled phase-field model with mechano-chemical contributions and its application to rafting of γ’ in CMSX-4. Computational Materials Science, 184 (2020) 109909. https://doi.org/10.1016/j.commatsci.2020.109909
[33] B. Böttger, J. Eiken, M. Apel, Multi-ternary extrapolation scheme for efficient coupling of thermodynamic data to a multi-phase-field model, Computational Materials Science, 108 (2015) 283–292. https://doi.org/10.1016/j.commatsci.2015.03.003
[34] B. Böttger, M. Apel, T. Jokisch, A. Senger, Phase-field study on microstructure formation in Mar-M247 during electron beam welding and correlation to hot cracking susceptibility. IOP Conference Series: Materials Science and Engineering, 861 (2020) 012072. https://doi.org/10.1088/1757-899X/861/1/012072
[35] B. Böttger, M. Apel, J. Eiken, P. Schaffnit, I. Steinbach, “Phase-Field Simulation of Solidification and Solid-State Transformations in Multicomponent Steels”, Steel Research International. 79 (2008) 608. https://doi.org/10.1002/srin.200806173