Study on arc behavior and droplet transfer mechanisms under complex paths

Abstract

Wire arc additive manufacturing (WAAM) is an economical and efficient technology for manufacturing large metal parts with complex physical states that are difficult to observe in situ. However, in-depth systematic research on the fluid flow state and droplet transition behavior in WAAM under complex paths is lacking. Firstly, the free surface of the molten pool was tracked using the volume-of-fluid (VOF) method. Subsequently, by integrating matrix transformation methods, the dual ellipsoidal heat source was varied over time, and its dynamic effects on the molten pool were studied. Finally, the shapes and sizes of the deposited bead and weld pool were determined. The results showed that the droplets brought heat and kinetic energy to the molten pool and that the kinetic energy of the molten pool was more easily dissipated on complex paths than on straight paths. The impact of droplets on the molten pool, creating a negative pressure, is one of the reasons for the precipitation of gas and the eventual formation of a unique bubble distribution. The primary reason for the tilt of the molten pool in the moving direction was the influence of the liquid tension and arc pressure. The simulated profiles of the deposited bead and droplet transfer are validated using experimental cross-sectional and high-speed camera images. The consistency between the simulation results and the experimental outcomes was good, aiding the precise control of specific requirements in future production.

Keywords

Wire arc additive manufacturing (WAAM) / Heat and mass transfer / Numerical simulation / Path strategy

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Funding

Taishan Scholar Foundation of Shandong Province(tsqn202211085)

Natural Science Foundation of Shandong Province(ZR2022ME106)

Qingdao Postdoctoral Science Foundation(QDBSH20240101039)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature