Numerical analysis of heat transfer and fluid flow in multilayer deposition of PAW-based wire and arc additive manufacturing

By X. Bai, Paul A. Colegrove, Jialuo Ding, Xiangman Zhou, C. Diao, Philippe Bridgeman, J. Hönnige, Haiou Zhang, Stewart W. Williams. International Journal of Heat and Mass Transfer, 2018

259 citations recorded by the source corpus.

Abstract A three-dimensional numerical model has been developed to investigate the fluid flow and heat transfer behaviors in multilayer deposition of plasma arc welding (PAW) based wire and arc additive manufacture (WAAM). The volume of fluid (VOF) and porosity enthalpy methods are employed to track the molten pool free surface and solidification front, respectively. A modified double ellipsoidal heat source model is utilized to ensure constant arc heat input in calculation in the case that molten pool surface dynamically changes. Transient simulations were conducted for the 1st, 2nd and 21st layer depositions. The shape and size of deposited bead and weld pool were predicted and compared with experimental results. The results show that for each layer of deposition the Marangoni force plays the most important role in affecting fluid flow, conduction is the dominant method of heat dissipation compared to convection and radiation to the air. As the layer number increases, the length and width of molten pool and the width of deposited bead increase, whilst the layer height decreases. However these dimensions remain constant when the deposited part is sufficiently high. In high layer deposition, where side support is absent, the depth of the molten pool at the rear part is almost flat in the Y direction. The profile of the deposited bead is mainly determined by static pressure caused by gravity and surface tension pressure, therefore the bead profile is nearly circular. The simulated profiles and size dimensions of deposited bead and molten pool were validated with experimental weld appearance, cross-sectional images and process camera images. The simulated results are in good agreement with experimental results.

Subfields: Automotive Engineering, Mechanical Engineering

View Paper: https://www.semanticscholar.org/paper/96c2570a59be65a9dc55175195741dae57487bb1

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Citations in the corpus

Wire and arc additive manufacturing: Opportunities and challenges to control the quality and accuracy of manufactured parts (2021, background): “Note that the deeppenetration andkeyhole formation are avoided in the WAAM process as it causes excessive fluidity harmful for forming keyhole induced defects [161].”
The Current State of Research of Wire Arc Additive Manufacturing (WAAM): A Review (2021, background): “The understanding and prediction of material transition is one of the challenging parts in welding-related process simulations and is currently under development not only for WAAM but welding in general [35,380,381,407].”
Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM) (2019, methodology): “[136] succeeded in accurately predicting bead geometry by simulating heat transfer and fluid flow.”