Wire Melting Behaviour in Wire Additive Manufacturing Using Induction Heating Process

Additive manufacturing has gained high appreciation in the manufacturing domain in the last decades. Various technologies have been developed for the application of additive manufacturing. Wire additive manufacturing is a key technology in this domain. The current research work is an attempt to understand the underlying physics of the wire additive manufacturing process with the induction heating application. In the current work melting behaviour of the wire during the induction heating process is investigated using numerical simulation. It has been observed that the AISI 4340 material is more suitable for wire additive manufacturing using the induction heating process compared to AA 6061 material. The maximum temperature recorded was 2420 K in case of AISI 4340 material and the same with the AA 6061 material is 950 K. The coil current and excitation frequency play a critical role in controlling the temperature of the wire during the heating process. The study reveals that the induction heating process can be suitably used for the wire additive manufacturing.