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Optimisation of interpass temperature and heat input for wire and arc additive manufacturing 5A06 aluminium alloy
Authors:Haibin Geng  Jinglong Li  Jiangtao Xiong  Xin Lin
Affiliation:1. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, PR China;2. Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, PR China;3. Shaanxi Key Laboratory of Friction Welding Technologies, Northwestern Polytechnical University, Xi’an, PR China
Abstract:Undulated surface appearance and inconsistent layer cross-sectional dimensions are two common types of appearance defects, which are formed owing to insufficient heat input and nonlinear time-varying thermal boundary condition of molten pool. Appropriate interpass temperature control and heat input regulations are effective ways to realise and maintain the consistent thermal boundary condition during bottom-up additive manufacturing process. Equivalent heat dissipation factor is used to synthetically characterise the variation of heat dissipation in process of additive manufacturing. Combing with Rosenthal's analytical solution, a theoretical model is developed to optimise interpass temperature and heat input for each layer deposition, so as to realise stable additive manufacturing. Finally a specification for the wire and arc additive manufacture procedure was designed according to the developed model which was verified effectively by manufacturing a wall part. It could also be a process design reference for other kinds of metal additive manufacturing.
Keywords:Wire and arc additive manufacturing  shape deposition control  thermal boundary condition  interpass temperature  heat input  equivalent heat dissipation  layer appearance  layer size
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