Analysis of metal transfer and weld geometry in hot-wire GTAW with indirect resistive heating
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RESEARCH PAPER
Analysis of metal transfer and weld geometry in hot-wire GTAW with indirect resistive heating T. Ungethüm 1 & E. Spaniol 1 & M. Hertel 1 & U. Füssel 1 Received: 4 December 2019 / Accepted: 28 August 2020 # The Author(s) 2020
Abstract In this publication, the different metal transfer modes of a hot-wire GTAW process with indirect resistive preheating of the wire are presented. The hot-wire GTAW process is characterized by an additional preheating unit that is used to heat the wire before it reaches the melt pool. Thus, to preheat the wire, the contact between the melt pool and the wire is not necessary. In order to examine the metal transfer of the wire, deposition welds are analysed using a high-speed camera with a laser light source as well as a data acquisition unit. The presented results comprise the impact analysis of the GTAW current, the hot-wire current, the wire feeding rate, the wire feeding angle as well as the wire feeding direction. The observed metal transfer modes can be characterized as either a constant melting bridge (cmb) between the wire and the melt pool or a recurring melting bridge (rmb). The analysis also reveals that the influence of the process parameters and thus the metal transfer mode on the bead properties is only marginal. Keywords WAAM . GTAW . TIG . Hot-wire . Metal transfer
1 Introduction The demands placed on industrial production, especially with regard to variant diversity and development time, are constantly growing. In order to respond better to customer wishes, companies have to reduce the development time for products on the one hand but on the other hand also need to be able to produce smaller batches and individual parts economically [1]. In the industrial production, the individual semi-finished products are usually produced by processes such as casting, extrusion or forging, subsequently processed further by machining and finally joined to form an assembly using various joining processes. When using additive manufacturing, on the other hand, the components are produced by building up layers of material and are then subjected to final processing. This type of component construction offers a number of advantages over conventional manufacturing methods. Due to Recommended for publication by Commission XII - Arc Welding Processes and Production Systems * T. Ungethüm [email protected] 1
Faculty of Mechanical Science and Engineering, Institute of Manufacturing Technology, Chair of Joining Technology and Assembly, TU-Dresden, Dresden, Germany
the layered structure, very sophisticated geometries with complicated undercuts and cavities, such as integrated cooling channels, can be realized [2]. In addition, the component can be manufactured near-net-shape, so that a considerable portion of the machining volume can be saved on milled parts, thus significantly reducing manufacturing time as well as costs. In recent years, a large number of processes have been developed for additive manufacturing of metal parts. At present, the most commonly used processe
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