Effect of reheating zones in additive manufacturing by means of electron beam metal wire deposition method

• Published in: CIRP journal of manufacturing science and technology Vol. 28; pp. 68 - 75
• Main Authors: Gaponova, Daria A., Rodyakina, Regina V., Gudenko, Alexander V., Sliva, Andrey P., Shcherbakov, Alexey V.
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.01.2020
• Subjects: Closed loop control; Computer simulation; Electron beam metal wire deposition method; Heat transfer; Mathematical model; Molten pool size; Electron beam metal wire deposition method; Closed loop control; Computer simulation; Mathematical model; Heat transfer; Molten pool size
• ISSN: 1755-5817; 1878-0016
• DOI: 10.1016/j.cirpj.2020.01.001

•The heat transfer model required for the study was created and described.•It was determined that during the depositing process, sub-layer temperatures increased continuously.•For quantitative verification of the model an experiment was conducted with a pyrometer.•It is shown that the developed model adequately recreates the temperature time-dependences.•Model can be applied to the study of control processes with feedback. The influence of heat transfer on molten pool size and temperature during the additive metal wire deposition process is shown. A mathematical model based on an energy equation that considers latent heat during melting is proposed. The model also examines the temperature dependences of thermophysical properties and the results are presented graphically. The analysis of computer simulation results reveals a gradual increase in molten pool size during deposition of a hollow cylindrical shape due to the influence of reheating zones. The results of experimental studies (conducted on ELA-40I and AELTK-12 electron beam installations) that confirm the simulation results are presented. Both sets of results suggest the need for feedback in order to control the molten pool temperature. As such, the proposed model is used to conduct a study involving temperature feedback. The analysis of time dependences obtained via simulation shows the fundamental possibility of stabilizing the temperature at a desired point. Limitations and possible improvements to this method are explored.