Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding
Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these re...
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| Format: | Article |
| Language: | English |
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MDPI AG
2022-06-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/12/6/984 |
| _version_ | 1797484389958942720 |
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| author | Rameez Israr Johannes Buhl Sebastian Härtel Markus Bambach |
| author_facet | Rameez Israr Johannes Buhl Sebastian Härtel Markus Bambach |
| author_sort | Rameez Israr |
| collection | DOAJ |
| description | Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters. |
| first_indexed | 2024-03-09T23:02:57Z |
| format | Article |
| id | doaj.art-65050badbd6f492d81120cd33d8e69ce |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-09T23:02:57Z |
| publishDate | 2022-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-65050badbd6f492d81120cd33d8e69ce2023-11-23T17:58:21ZengMDPI AGMetals2075-47012022-06-0112698410.3390/met12060984Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc WeldingRameez Israr0Johannes Buhl1Sebastian Härtel2Markus Bambach3Chair of Hybrid Manufacturing, Brandenburg University of Technology Cottbus–Senftenberg, 03046 Cottbus, GermanyChair of Hybrid Manufacturing, Brandenburg University of Technology Cottbus–Senftenberg, 03046 Cottbus, GermanyChair of Hybrid Manufacturing, Brandenburg University of Technology Cottbus–Senftenberg, 03046 Cottbus, GermanyAdvanced Manufacturing Lab, ETH Zurich, Leonhardstrasse 27, 8092 Zurich, SwitzerlandCladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters.https://www.mdpi.com/2075-4701/12/6/984Additive Manufacturing (AM)Wire Arc Additive Manufacturing (WAAM)weld claddingresidual stressesreinforcementhole drilling method |
| spellingShingle | Rameez Israr Johannes Buhl Sebastian Härtel Markus Bambach Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding Metals Additive Manufacturing (AM) Wire Arc Additive Manufacturing (WAAM) weld cladding residual stresses reinforcement hole drilling method |
| title | Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding |
| title_full | Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding |
| title_fullStr | Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding |
| title_full_unstemmed | Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding |
| title_short | Reinforcement of Tooling Using Residual Stresses Generated by Cladding by Arc Welding |
| title_sort | reinforcement of tooling using residual stresses generated by cladding by arc welding |
| topic | Additive Manufacturing (AM) Wire Arc Additive Manufacturing (WAAM) weld cladding residual stresses reinforcement hole drilling method |
| url | https://www.mdpi.com/2075-4701/12/6/984 |
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