Title: Investigation of pulse advance cold metal transfer on aluminium wire arc additive manufacturing

Authors: K.F. Ayarkwa; S. Williams; J. Ding

Addresses: Welding Engineering and Laser Processing Centre, Cranfield University, Bedfordshire, MK43 0AL, UK ' Welding Engineering and Laser Processing Centre, Cranfield University, Bedfordshire, MK43 0AL, UK ' Welding Engineering and Laser Processing Centre, Cranfield University, Bedfordshire, MK43 0AL, UK

Abstract: This study sought to investigate the effect of process parameters on linear wall dimensions when using the pulse advance cold metal transfer process for aluminium wire arc additive manufacturing. Firstly, a process envelope was developed and the limit of the wire feed speed to travel speed ratio determined. A limiting range of wire feed speeds was also identified. The results showed that the key factor for wall dimensions is the wire feed speed to travel speed ratio. It was observed that increasing the ratio increased the effective wall width, total wall width, layer height and surface waviness. Microstructure analysis conducted showed that walls were characterised mainly by equiaxed and dendrite grains. It was observed that the porosity increased with increasing wire feed speed to travel speed ratio. Using this process, an effective wall width range of 4.9-8 mm was achieved.

Keywords: cold metal transfer; pulse advance arc; aluminium alloys; porosity; equiaxed grains; dendrite grains; additive manufacturing; process parameters; linear wall dimensions; wire feed speed; travel speed; wall width; layer height; surface waviness; microstructure.

DOI: 10.1504/IJRAPIDM.2015.073547

International Journal of Rapid Manufacturing, 2015 Vol.5 No.1, pp.44 - 57

Received: 07 Sep 2015
Accepted: 21 Oct 2015
Published online: 11 Dec 2015 *

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