IIW Welding Research & Collaborations Colloquium Limburg, Germany, 28th – 30th October 2015
University Federal of Uberlândia – MG – Brazil
Arc Welding Additive Manufacturing: The Potentialities for Aluminum Alloys Leandro João da Silva, Ph.D. student
University Federal of Uberlândia – MG – Brazil
Center for Research and Development of Welding Process - Laprosolda Federal University of Uberlândia – UFU - Brazil
Laprosolda: Facilities – 700 m2 of dedicated area (labs and offices)
Laprosolda Facilities
Laprosolda Facilities
Laprosolda Facilities
Laprosolda – Arc Weding Additive Manufacturing Water calorimetric plate holder
Walls processed by CMT
Introduction: Additive Manufacturing (AM) AM uses an approach layer-by-layer to produce free-form components.
1- CAD 3d modeling 2- Divide modeling in layers 3- CNC trajetory of each layer 4– Deposition layer-by-layer
3
4
1
2
Additive Manufacturing Traditional Process
Additive Manufacturing
Subtractive
Additive
Additive Manufacturing Machining
Rapid Prototyping
Subtractive
Additive
Additive Manufacturing At the beginning, AM was used as a tool to help designers during product development stage. Currently, this concept was extrapolated and it is possible to produce functional components with AM.
MMAM
Direct Metal Deposition
Rapid Prototyping
Functional Component
Basic Metal AM system Laser
Arc
Energy Source
Motion system Powder
Wire Feed system
Robot arm/ CNC Systems
Basic Metal AM system: Heating Source LASER
ARC
Powder
Low deposition rate (0,1-0,2 kg/h) Low material efficiency (10-60%) High cost (equipament and part) High level of part complexity
Wire
High deposition rate (1–5 kg/h) High material efficiency (90%) Low cost (equipament and part) Low level of part complexity
Arc Welding Additive Manufacturing
The main arc welding processes used in AM and their features Arc welding process
Features
Cold Metal Transfer (CMT)
High quality, zero spatter, low heating input process with reciprocating consumable wire electrode.
TIG
High quality, separate wire process, with no consumable electrode.
Plasma
High stability, separate wire process, with no consumable hidden electrode. Stewart Williams, 2012 – Cranfield University
Arc Welding Additive Manufacturing The main materials and process used in arc welding additive manufacturing Material Mild steel High strength steel Ti6Al4V
Aluminum alloys Stainless stell
Arc process CMT CMT TIG, PLASMA, CMT CMT CMT
Stewart Williams, 2012 – Cranfield University
AM: Potentialities for Aluminiun Alloys
Production of a great number of parts justify the cost to manufacture a permanent mold for aluminum die casting. However, how to produce a medium/small amount or customized components?
In these cases, AM might be a solution. Another advantage of AM of Aluminium alloys would be better mechanical properties
Research Trends Residual Stress mitigating
Processing parameters optimization
Arc Welding Addtive Manufacturig
Processing control
Avoidance anisotropy
What have been done in these subjects?
Residual stress
• High pressure interpass rolling • Back to Back Building • Laser pinning
Processing
• Improve arc stability • Improve the energy density • Active parameters control
Anisotropy
• Thermal pulsation • Metallurgical agents • High pressure interpass rolling
Processing control
• Shape measurement • Thermal control • Acoustic spectroscopy
Laprosolda
UFU-Welding group
The presenter thanks very much the organizers and sponsors for making possible my participation in the event
