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Russian Develop WAAM Process for Al–Mg–Mn Using Controlled Short-Circuiting Metal Transfer

Metal News - Published on Wed, 09 Sep 2020

Image Source: WAAM Process
During experiments on high-performance Wire Arc Additive Manufacturing researchers from Peter the Great St Petersburg Polytechnic University produced metal with unique ductility. The ductility is three times higher than specified in the standard. The increase of WAAM productivity led to the discovery of the unique properties of aluminum. Elongation of specimens during tensile tests of produced metal increased from 12 to 41% compared to its standard properties for the same chemical composition. It means that the material will be able to perform longer with the same loading conditions. The developed WAAM technology with higher process rates helps to achieve better material performance.

Wire Arc Additive Manufacturing is a method for manufacturing high-scale metal objects. This method utilizes recent developments in welding to achieve better performance and higher process rates. Higher performance requires higher metal deposition rates, which implies higher heat input that negatively affects the manufacturing process. In the present study, a high-performance controlled short-circuiting metal transfer process at a wire feed rate of 12 m/min for WAAM with an Al–Mg–Mn alloying system was developed. The arc current and voltage waveforms were studied by oscillogram processing and then modified to reduce the energy input in comparison with a self-regulated gas metal arc welding process. The newly developed process was implemented to manufacture sample parts at a travel speed of up to 150 cm/min. The modified waveforms in combination with an increased travel speed led to a decrease in heat input, which appeared to be 16% lower than that of a conventional self-regulated process. Decreased heat input led to an improved geometry preservation stability at high process rates (up to 2.2 kg/h). Study of the mechanical properties showed that the elongation of the tensile samples was up to 41%. This increase in elongation was explained through macro- and microstructure analysis.

The scientists also plan on studying properties of the produced material under cyclic (fatigue) loading since the published study was based on the analysis performed for static loading. Researchers plan to test the hypothesis that materials with increased ductility show better fatigue performance.

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Posted By : Yogender Pancholi on Wed, 09 Sep 2020
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