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<p>Submerged Arc Additive Manufacturing (SAAM) overcomes key drawbacks of Wire Arc Additive Manufacturing (WAAM) by reducing residual stresses, anisotropy, and improving surface finish. However, the granular flux in SAAM obscures the arc column, making direct arc pressure measurement unfeasible, impeding process optimisation. Accurate in situ pressure modelling is crucial, as pressure distribution within the arc directly influences molten pool behaviour, bead geometry and mechanical properties. Despite its significance, limited research exists on real-time arc pressure estimation in SAAM, necessitating robust analytical approaches. This paper presents the development of an analytical model to predict arc pressure distribution in SAAM, aiming to bridge the gap due to experimental limitations. The model incorporates process inputs, material properties and geometric parameters to reflect realistic manufacturing conditions and employs rational assumptions, including Gaussian heat flux distribution, double ellipsoid arc column and temperature-dependent material properties. The model’s predictions deviate by 9.31% from experimental results, validating its accuracy. Key findings include the impact of wire diameter, stick-out length, current, voltage and deposition speed on pressure distribution, bead width and penetration depth, where thinner wires and higher currents are found to enhance penetration and surface finish, whilst longer stick-out lengths increase bead width. In addition, the study reveals that higher pressure differences within the arc column lead to tighter compaction of the granular flux, reducing permeability and altering gas escape dynamics. Understanding and optimising these pressure dynamics is crucial for tailoring bead characteristics and mechanical properties in SAAM, paving the way for its broader application in manufacturing high-quality metallic components.</p>

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A thermo-physical model for computation of in situ arc pressure during the submerged arc-based additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月22日

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  • Suraj Goala,
  • Shrikrishna N. Joshi

摘要

Submerged Arc Additive Manufacturing (SAAM) overcomes key drawbacks of Wire Arc Additive Manufacturing (WAAM) by reducing residual stresses, anisotropy, and improving surface finish. However, the granular flux in SAAM obscures the arc column, making direct arc pressure measurement unfeasible, impeding process optimisation. Accurate in situ pressure modelling is crucial, as pressure distribution within the arc directly influences molten pool behaviour, bead geometry and mechanical properties. Despite its significance, limited research exists on real-time arc pressure estimation in SAAM, necessitating robust analytical approaches. This paper presents the development of an analytical model to predict arc pressure distribution in SAAM, aiming to bridge the gap due to experimental limitations. The model incorporates process inputs, material properties and geometric parameters to reflect realistic manufacturing conditions and employs rational assumptions, including Gaussian heat flux distribution, double ellipsoid arc column and temperature-dependent material properties. The model’s predictions deviate by 9.31% from experimental results, validating its accuracy. Key findings include the impact of wire diameter, stick-out length, current, voltage and deposition speed on pressure distribution, bead width and penetration depth, where thinner wires and higher currents are found to enhance penetration and surface finish, whilst longer stick-out lengths increase bead width. In addition, the study reveals that higher pressure differences within the arc column lead to tighter compaction of the granular flux, reducing permeability and altering gas escape dynamics. Understanding and optimising these pressure dynamics is crucial for tailoring bead characteristics and mechanical properties in SAAM, paving the way for its broader application in manufacturing high-quality metallic components.