A novel cold wire gas metal arc (CW-GMA) process for high productivity additive manufacturing

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dc.contributor.authorWang, Chong
dc.contributor.authorWang, Jun
dc.contributor.authorBento, João
dc.contributor.authorDing, Jialuo
dc.contributor.authorRodrigues Pardal, Goncalo
dc.contributor.authorChen, Guangyu
dc.contributor.authorQin, Jian
dc.contributor.authorSuder, Wojciech
dc.contributor.authorWilliams, Stewart
dc.date.accessioned2023-07-13T12:15:58Z
dc.date.available2023-07-13T12:15:58Z
dc.date.issued2023-07-01
dc.description.abstractWire-arc directed energy deposition (DED) is suitable for depositing large-scale metallic components at high deposition rates. In order to further increase productivity and efficiency by reducing overall manufacturing time, higher deposition rates are desired. However, the conventional gas metal arc (GMA) based wire-arc DED, characterised by high energy input, normally results in high remelting and reheating at relatively high deposition rates, reducing the process efficiency and deteriorating the mechanical performance. In this study, a novel wire-arc DED process with the combination of a GMA and an external cold wire, namely cold wire-gas metal arc (CW-GMA), was proposed for achieving high deposition rate and low material remelting. The maximum deposition rates at different levels of energy input were investigated, with the highest deposition rate of 14 kg/h being achieved. An industrial-scale component weighing 280 kg was built with this process at a high deposition rate of around 10 kg/h, which demonstrated the capability of the process for high productivity application. It was also found that, due to the addition of the cold wire, the remelting was reduced significantly. The working envelope and geometric process model for the CW-GMA process was developed, which can be used to avoid defects in parameter selection and predict the geometry of single-pass wall structures. Moreover, the addition of the cold wire in the CW-GMA process reduced the specific energy density, leading to a reduction in both grain size and anisotropy, which improved the mechanical properties with increased strength and reduced anisotropy.en_UK
dc.description.sponsorshipInnovate UK: 53610 Engineering and Physical Sciences Research Council (EPSRC): EP/R027218/1en_UK
dc.identifier.citationWang C, Wang J, Bento J, et al., (2023) A novel cold wire gas metal arc (CW-GMA) process for high productivity additive manufacturing, Additive Manufacturing, Volume 73, July 2023, Article Number 103681en_UK
dc.identifier.eissn2214-8604
dc.identifier.issn2214-7810
dc.identifier.urihttps://doi.org/10.1016/j.addma.2023.103681
dc.identifier.urihttps://dspace.lib.cranfield.ac.uk/handle/1826/19983
dc.language.isoenen_UK
dc.publisherElsevieren_UK
dc.rightsAttribution 4.0 International*
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/*
dc.subjectWire-arc DEDen_UK
dc.subjectHigh deposition rateen_UK
dc.subjectProcess modelen_UK
dc.subjectMicrostructureen_UK
dc.subjectMechanical propertiesen_UK
dc.titleA novel cold wire gas metal arc (CW-GMA) process for high productivity additive manufacturingen_UK
dc.typeArticleen_UK

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