A strategic approach to minimize lack of fusion defects in wire arc additive manufacturing
摘要
This study investigates the wire arc additive manufacturing (WAAM) process, focusing on the effects of different weld deposition strategies on the quality of deposited blocks. To address the prevalent lack-of-fusion defects in WAAM, two blocks are deposited: one using conventional additive manufacturing (C-AM), where the block is built by side-by-side weld bead deposition, and another using strategic additive manufacturing (S-AM), which employs a combination of cold metal transfer (CMT), CMT + weaving, and pulsed gas metal arc welding (P-GMAW) in a logical sequence. In the S-AM approach, the overlapping distance initially based on a parabolic function (0.667w) did not result in proper overlap, leading to the development of a modified flat-top model using a polynomial fit. This adjustment achieved an overlapping distance of approximately 0.6w between CMT + weaving conditions. Higher levels of lack-of-fusion defects were observed in the initial tracks of both S-AM and C-AM blocks, likely due to the higher cooling rates caused by the substrate acting as a significant heat sink. Defects sized 0–10 mm2 were the most common in both deposition strategies, while defects sized 31–40 mm2 were the least common. Larger lack-of-fusion defects were almost non-existent in the S-AM block. The S-AM block showed a 73% reduction in lack-of-fusion defects compared to the C-AM block, demonstrating the effectiveness of the strategic deposition approach in improving the quality of WAAM components.