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<p>Wire arc additive manufacturing (WAAM) is often used to manufacture defect‑free, complex non‑ferrous components though non-uniform thermal behaviour over subsequent deposited layers is a major concern. The present work addresses the interaction effect of wire feed rate and dwell time on successive layers deposition in bidirectional path using robotic WAAM integrated with metal inert gas (MIG) welding machine. The cold metal transfer (CMT) in pulsed current mode was considered for the deposition of magnesium rich Al5356 alloy on a substrate. The real time deviation in thermal characteristics of the hot deposited molten pool was captured by high-speed thermography. The solidified structures were scanned through blue light scanner for the development of digitized geometric models for dimensional analysis of longitudinal/transverse sections. The deviations in thermal cycles, i.e. peak temperature, cooling rate, temperature gradient in longitudinal/transverse direction over molten metallic pool in successive depositions were analysed. An attempt was made to develop response surface-based regression models of deposited structure using thermal features of the molten pool which showed high prediction accuracy. The non-uniform stretched molten pool at lower heat input together with higher interlayer dwell time of 60&#xa0;s was primary responsible for poor symmetry in metal deposition. The lateral deviation was highly significant (≥ 11%) for geometric mismatch due to drastic fluctuations in thermal cycles in deposited metal while it was improved (≤ 3%) at higher wire feed rate and low dwelling period. The materials utilization efficiency was thus found to be improved (≥ 80.8%) at this parametric condition. The high wire speed rate along with low dwell time improves thermal and geometric stability, reduces lateral deviations, and increases material utilization efficiency.</p>

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Monitoring of metal deposition and process stability in wire arc additive manufacturing of Al5356 alloy using arc thermography

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Babuli Kumar Jena,
  • Kamal Pal,
  • Shashi Bhushan Prasad,
  • G. Kranthi Kumar

摘要

Wire arc additive manufacturing (WAAM) is often used to manufacture defect‑free, complex non‑ferrous components though non-uniform thermal behaviour over subsequent deposited layers is a major concern. The present work addresses the interaction effect of wire feed rate and dwell time on successive layers deposition in bidirectional path using robotic WAAM integrated with metal inert gas (MIG) welding machine. The cold metal transfer (CMT) in pulsed current mode was considered for the deposition of magnesium rich Al5356 alloy on a substrate. The real time deviation in thermal characteristics of the hot deposited molten pool was captured by high-speed thermography. The solidified structures were scanned through blue light scanner for the development of digitized geometric models for dimensional analysis of longitudinal/transverse sections. The deviations in thermal cycles, i.e. peak temperature, cooling rate, temperature gradient in longitudinal/transverse direction over molten metallic pool in successive depositions were analysed. An attempt was made to develop response surface-based regression models of deposited structure using thermal features of the molten pool which showed high prediction accuracy. The non-uniform stretched molten pool at lower heat input together with higher interlayer dwell time of 60 s was primary responsible for poor symmetry in metal deposition. The lateral deviation was highly significant (≥ 11%) for geometric mismatch due to drastic fluctuations in thermal cycles in deposited metal while it was improved (≤ 3%) at higher wire feed rate and low dwelling period. The materials utilization efficiency was thus found to be improved (≥ 80.8%) at this parametric condition. The high wire speed rate along with low dwell time improves thermal and geometric stability, reduces lateral deviations, and increases material utilization efficiency.