Analysis of the solid wire dip in the GMAW-CMT melting pool as a means for enhancing additive manufacturing

This work presents an analysis of the influence of solid wire dip in the melting pool using Cold Metal Transfer (CMT) on process and weld characteristics. A better understanding of the thermomechanical phenomena involved in the metal transfer and the resulting characteristics of the weld bead are ne...

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Bibliographic Details
Published inJournal of the Brazilian Society of Mechanical Sciences and Engineering Vol. 45; no. 3
Main Authors Marques, Cleber, Pereira, Alex Sandro, Silva, Régis H. G., Galeazzi, Daniel, Pigozzo, Ivan Olszanski
Format Journal Article
LanguageEnglish
Published Berlin/Heidelberg Springer Berlin Heidelberg 01.03.2023
Springer Nature B.V
Subjects
Additive manufacturing
Cold welding
Data acquisition
Engineering
Gas metal arc welding
Manufacturing
Mechanical Engineering
Melting
Technical Paper
Videography
Wire
High-speed videography-HSV
GMAW-CMT process monitoring
Cold metal transfer
Metal 3D Print
Offshore welding applications
WAAM
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Summary:This work presents an analysis of the influence of solid wire dip in the melting pool using Cold Metal Transfer (CMT) on process and weld characteristics. A better understanding of the thermomechanical phenomena involved in the metal transfer and the resulting characteristics of the weld bead are needed for improving the application of wire arc additive manufacturing (WAAM) in non-enclosed environments. Experiments monitoring was conducted through high-speed videography, allowing both the wire dynamic movement characterization and synchronized analysis of the electrical signals via a data acquisition system with a sampling frequency of 10 kHz. For this investigation, a demand for technological development regarding data acquisition of the wire´s dynamic movement was identified, which led to a novel resource and methodology for the study of the Gas Metal Arc Welding (GMAW)-CMT process. It was concluded that the solid wire dip in the melting pool has an impact on wire melting rate, whereby an increase of up to 29% may be achieved by increasing the dip, for the conditions of the present study. The weld bead geometry obtained showed satisfactory characteristics, suitable for wire arc additively manufactured components.
ISSN:1678-5878
1806-3691
DOI:10.1007/s40430-023-04054-8