Influence of wire-arc additive manufacturing path planning strategy on the residual stress status in one single buildup
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ORIGINAL ARTICLE
Influence of wire-arc additive manufacturing path planning strategy on the residual stress status in one single buildup layer Chi Zhang 1 & Chen Shen 1 & Xueming Hua 1 & Fang Li 1 & Yuelong Zhang 1 & Yanyan Zhu 1 Received: 28 June 2020 / Accepted: 24 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract In recent years, the significant residual stress in the wire-arc additively manufactured components has been continuously one of the most concerning issues for the further development of the wire-arc additive manufacturing (WAAM) technology. Although many pre/post processing methods have been proved capable of modifying the residual stress, few works have been conducted to reduce the residual stress using appropriate path planning. In the present research, a WAAM path planning strategy is developed combining both zigzag and contour-offset methods, which aims to obtain a single WAAM deposition buildup layer with both optimal outline accuracy and residual stress status. The path planning and residual stress measurement processes have been carefully designed to acquire reasonable results. According to the residual stress results measured using X-ray diffraction method, the arc deposits finished with more contour-offset paths contain smaller tensile residual stresses, which is due to the hooping function of the outer contour deposit path to the inner deposit. Therefore, it can be concluded that the offsetting of the external contours before zigzag filling the internal dimensions is beneficial to both the residual stress distribution and shape outline accuracy of the WAAM buildup layer. Keywords Wire-arc additive manufacturing . Path planning . Residual stress . Arc welding
1 Introduction In recent years, metal additive manufacturing (AM) technology has been developing rapidly due to its high shaping flexibility and efficiency compared with the traditional material forming methods [1]. The layer-by-layer deposition nature of AM technique requires significantly lower postprocessing workload and improves the material utilization rate. Meanwhile, along with the further development of the technique, more and more metals have been proved feasible of being additively manufactured [2, 3]. To date, the metal AM technique has been widely used in medical and aerospace industries. It has also been considered as one of the most promising part manufacturing technology in mass production * Chen Shen [email protected] * Xueming Hua [email protected] 1
Shanghai Key Lab of Materials Laser Processing and Modification, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
fields such as automotive and shipbuilding industries [4–6]. However, most of the current existing AM methods are still not available for mass production industries because of the unacceptable high cost and low material deposition rate. Current metal AM technologies can be categorized using the heating power source (e.g., laser, electron beam, electric arc), the filler mate
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