Wire arc additive manufacturing of porous metal using welding pore defects
A novel wire arc additive manufacturing process is proposed to produce porous metal (PM). The innovation is to convert harmful welding pore defects into a beneficial structure of PM, and then the PM parts can be additive manufactured layer by layer. Air was transferred to the molten pool as pore pro...
| Main Authors: | , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2023-09-01
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| Series: | Materials & Design |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127523006287 |
| _version_ | 1797671465044148224 |
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| author | Daxin Ren Xianli Ba Zhaodong Zhang Zhao Zhang Kunmin Zhao Liming Liu |
| author_facet | Daxin Ren Xianli Ba Zhaodong Zhang Zhao Zhang Kunmin Zhao Liming Liu |
| author_sort | Daxin Ren |
| collection | DOAJ |
| description | A novel wire arc additive manufacturing process is proposed to produce porous metal (PM). The innovation is to convert harmful welding pore defects into a beneficial structure of PM, and then the PM parts can be additive manufactured layer by layer. Air was transferred to the molten pool as pore promoters to maximize the formation of the welding pore defects. The triple-wire indirect arc process was used for fabricating multi-layer parts to reduce interlayer filling. The primary advantage is that the process can directly produce macro-pore structures rather than depositing pore walls along micro paths in laser additive manufacturing. The uniform diameter of the pore ranges from 500 to 2700 μm, and the typical porosity is 64%, 49%, and 87%. The process could achieve a high deposition rate of 11.5 kg/h. Due to martensite formation, the pore walls can achieve high microhardness of over 200 HV. |
| first_indexed | 2024-03-11T21:15:56Z |
| format | Article |
| id | doaj.art-67d7104e7a1d451cab747c5161e7da50 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-03-11T21:15:56Z |
| publishDate | 2023-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-67d7104e7a1d451cab747c5161e7da502023-09-29T04:43:23ZengElsevierMaterials & Design0264-12752023-09-01233112213Wire arc additive manufacturing of porous metal using welding pore defectsDaxin Ren0Xianli Ba1Zhaodong Zhang2Zhao Zhang3Kunmin Zhao4Liming Liu5School of Automotive Engineering, Dalian University of Technology, China; Key Laboratory of Liaoning Advanced Welding and Joining Technology, ChinaSchool of Materials Science and Engineering, Dalian University of Technology, ChinaKey Laboratory of Liaoning Advanced Welding and Joining Technology, China; School of Materials Science and Engineering, Dalian University of Technology, China; Corresponding authors at: Key Laboratory of Liaoning Advanced Welding and Joining Technology, China.Key Laboratory of Liaoning Advanced Welding and Joining Technology, China; Department of Engineering Mechanics, Dalian University of Technology, ChinaHezhong New Energy Automotive Co., Ltd., ChinaKey Laboratory of Liaoning Advanced Welding and Joining Technology, China; School of Materials Science and Engineering, Dalian University of Technology, China; Corresponding authors at: Key Laboratory of Liaoning Advanced Welding and Joining Technology, China.A novel wire arc additive manufacturing process is proposed to produce porous metal (PM). The innovation is to convert harmful welding pore defects into a beneficial structure of PM, and then the PM parts can be additive manufactured layer by layer. Air was transferred to the molten pool as pore promoters to maximize the formation of the welding pore defects. The triple-wire indirect arc process was used for fabricating multi-layer parts to reduce interlayer filling. The primary advantage is that the process can directly produce macro-pore structures rather than depositing pore walls along micro paths in laser additive manufacturing. The uniform diameter of the pore ranges from 500 to 2700 μm, and the typical porosity is 64%, 49%, and 87%. The process could achieve a high deposition rate of 11.5 kg/h. Due to martensite formation, the pore walls can achieve high microhardness of over 200 HV.http://www.sciencedirect.com/science/article/pii/S0264127523006287Porous metalAdditive manufacturingPorosity defectsArc welding |
| spellingShingle | Daxin Ren Xianli Ba Zhaodong Zhang Zhao Zhang Kunmin Zhao Liming Liu Wire arc additive manufacturing of porous metal using welding pore defects Materials & Design Porous metal Additive manufacturing Porosity defects Arc welding |
| title | Wire arc additive manufacturing of porous metal using welding pore defects |
| title_full | Wire arc additive manufacturing of porous metal using welding pore defects |
| title_fullStr | Wire arc additive manufacturing of porous metal using welding pore defects |
| title_full_unstemmed | Wire arc additive manufacturing of porous metal using welding pore defects |
| title_short | Wire arc additive manufacturing of porous metal using welding pore defects |
| title_sort | wire arc additive manufacturing of porous metal using welding pore defects |
| topic | Porous metal Additive manufacturing Porosity defects Arc welding |
| url | http://www.sciencedirect.com/science/article/pii/S0264127523006287 |
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