ijier logo

Measurement and Simulation of Low Carbon Steel Alloy Deposit Temperature in plasma Arc Welding Additive Manufacturing

Authors

  • Abdullah Alhuzaim

    Jubail Technical Institute, Saudi Arabia

    Author

  • R. Bruce Madigan

    Montana Tech of The University of Montana, USA

    Author

DOI:
https://doi.org/10.31686/ijier.vol2.iss6.200
Keywords:
Array, Array, Array, Array, Array, Array
Abstract

Additive manufacturing has the potential to produce near-net shape parts directly from weld metal. Prior work has proved that it is possible to directly manufacture components with complex geometric features and with good productivity. However, under high productivity conditions, deposit temperature increases to a level that it is no longer possible to develop appropriate deposit microstructure and therefore mechanical properties. In this study, Plasma Arc welding was used to produce experimental deposits of 1018 low carbon steel under various conditions. An analytical heat flow model was developed to study the influence of interlayer wait time on deposit temperature and therefore grain size and hardness. The results of the model indicated that as wall height increased, the rate of deposit heat removal by conduction to the substrate decreased leading to a higher preheat temperature after a fixed interlayer wait time causing grain size to increase as wall height increased. However, the model results also show that as wall height increased, the deposit surface area from which heat energy is lost via convection and radiation increased. The model also demonstrated that the use of a means of forced convection to rapidly remove heat from the deposit could be an effective way to boost productivity and maintain smaller grain size and therefore higher hardness and strength in the deposit.

References

C.O. Brown, E.M. Breinan and B.H. Kear. Method for Fabricating Articles by Sequential Layer Deposition. 4.323.756 U.S. , 1982.

Edmonds, M.D. McAninch and D.P. Method and Apparatus for Building a Workpiece by Deposit Welding. 4,775,092. U.S., 1988.

Electron Beam Freeform Fabrication Fabrication: A Metal Deposition Apparatus to Build Components Directly from CAD. Taminger, Karen. Arlington,

Texas : NASA Langley Research Center, March 26-

, 2008. available at technologygateway.nasa.gov/docs/EBF3Overview.pdf.

Electron Beam Freeform Fabrication for Cost

Effective Near-Net Shape Manufacturing. Hafley,

Karen M. Taminger and Robert A. s.l. : NASA

Langley Research Center. Metals & ThermalStructures Branch. Mail Stop 188A, Hampton, VA 23681-2199 USA available at technologygateway.nasa.gov/docs/20080013538_200 8013396.pdf.

Direct Digital Manufacturing of Metallic

Components: Direct Digital Manufacturing of

Metallic Components Affordable, Durable, and

Structurally Efficient Airframes. Frazier, W.E. at the Holiday Inn, Solomons Island, MD : s.n., 11 - 12 May 2010, Vision and Roadmap.

Sciaky Manufacturing. [Online] http://www.sciaky.com/direct_manufacturing.html.

Qualification of Metallic Materials and Structures for Aerospace Applications. William Frazier, Don Polakovics, and Wayne Koegel. March 2001, JOM.

Shaped Metal Deposition of a Nickel Alloy for Aero Engine Applications. Clark, D., M. R. Bache, and M. T. Whittaker. 2008, Journal of Materials Processing Technology 203, pp. 439-448. DOI: https://doi.org/10.1016/j.jmatprotec.2007.10.051

Stavinoha, Joe N. Investigation Of Plasma Arc Welding As A Method For The Additive Manufacturing Of Ti-6Al-4V Alloy Components. Butte : Montana Tech, 2012.

Measurement And Simulation Of Titanium Alloy

Deposit Temperature In Electron Beam Additive

Manufacturing. Madigan, R. Bruce, Sean F. Riley, Mark J. Cola, Vivek R. Dave, and John E.

Talkington. Chicago, Illinois : ASM International,, 2012. Ninth International Trends in Welding Research Conference.

Incropera, Frank P., David P. DeWitt, Theodore L. Bergman, and Adrienne S. Lavine.

Introduction to Heat Transfer. Fifth ed. Hoboken. New Jersey : John Wiley & Sons, Inc., 2007.

Donachie, Matthew J. Titanium Technical Guide. Second. Materials Park, Ohio : ASM International, 2000. DOI: https://doi.org/10.31399/asm.tb.ttg2.9781627082693

Messler, Robert W. Principles Of Welding:

Processes, Physics, Chemistry, And Metallurgy. s.l. : Weinheim, Baden-Württemberg, Germany: WileyVCH., 2004.

Association, Staff of Research and Education. The Handbook of Mechanical Engineering. Piscataway, New Jersey : Research and Education Association., 2004.

Alhuzaim, Abdullah F. INVESTIGATION IN THE USE OF PLASMA ARC WELDING AND

ALTERNATIVE FEEDSTOCK DELIVERY METHOD IN ADDITIVE MANUFACTURE. Butte, MT :

Montana Tech of the university of Montana, 2014. Available at http://www.abdullahalhuzaim.com/wpcontent/uploads/2014/05/Additive-Manufacture.pdf

Downloads
Published
2014-06-01
Issue
Vol. 2 No. 6 (2014): International Journal for Innovation Education and Research
Section
Journal Articles
License

Copyright (c) 2014 Abdullah Alhuzaim, R. Bruce Madigan

Creative Commons License

This work is licensed under a Creative Commons Attribution-NoDerivatives 4.0 International License.

Copyrights for articles published in IJIER journals are retained by the authors, with first publication rights granted to the journal. The journal/publisher is not responsible for subsequent uses of the work. It is the author's responsibility to bring an infringement action if so desired by the author for more visit Copyright & License.

How to Cite

Alhuzaim, A., & Madigan, R. B. (2014). Measurement and Simulation of Low Carbon Steel Alloy Deposit Temperature in plasma Arc Welding Additive Manufacturing. International Journal for Innovation Education and Research, 2(6), 113-127. https://doi.org/10.31686/ijier.vol2.iss6.200