Active and Passive Thermal Management in Wire Arc Additive Manufacturing

This article presents innovative approaches for managing residual stresses and distortion in additive manufacturing (AM) of metal components (baseplate material: EN8; filler wire ER70S-6). The experiments are conducted with two thermal management—passive active. passive approach is performed by varying the selected process parameters to study their effect on distortion. chosen current, torch speed, geometry, continuous or a delay deposition, cooling arrangement. Based understanding gained from approach, active management was implemented insulating substrate without adaptive current heating substrate. experimental results were corroborated simulation understand better. A comparative hardness made based T8/5 extracted simulation. These simulations endorse as effective tools that can alter stress pattern mechanical properties an AM component. investigation concludes lead higher heat input vis-à-vis increase decrease speed On other hand, affect rate distribution geometry stresses. When traverse a/b ratio kept same, heated base reduced 1.226 mm 0.431 mm, 65% reduction compared management. Additionally, maximum 492.31 MPa 250.68 MPa, decreasing 418.57 372 MPa. Overall, resulted 63% distortion, lowering it 1.35 0.50 using external heating. difficult complete because in-process expected be manufactured management, e.g., measure manage Thermal techniques depend geometry; instance, concave surface, self-heating, reduces has relatively less variation hardness.