Purpose

This paper aims at fabricating large metallic components with high deposition rates, low equipment costs through wire and wire and arc additive manufacturing (WAAM) method, in order to achieve the morphology and mechanical properties of manufacturing process, a bead morphology prediction model with high precision for ideal deposition of every pass was established.

Design/methodology/approach

The dynamic response of the process parameters on the bead width and bead height of cold metal transfer (CMT)-based AM was analyzed. A laser profile scanner was used to continuously capture the morphology variation. A prediction model of the deposition bead morphology was established using response surface optimization. Moreover, the validity of the model was examined using 15 groups of quadratic regression analyzes.

Findings

The relative errors of the predicted bead width and height were all less than 5% compared with the experimental measurements. The model was then preliminarily used with necessary modifications, such as further considering the interlayer process parameters, to guide the fabrication of complex three-dimensional components.

Originality/value

The morphology prediction of WAAMed bead is a critical issue. Most research has focused on the formability and defects in CMT-based WAAM and little research on the effect of process parameters on the morphology of the deposited layer in CMT-based WAAM has been conducted. To test the sensitivities of the processing parameters to bead size, the dynamic response of key parameters was investigated. A regression model was established to guide the process parameter optimization for subsequent multi-layer or component deposition.

中文翻译：

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基于 CMT 线材和电弧增材制造工艺参数动态响应的焊道尺寸模型

目的

本文旨在通过线材和线材和电弧增材制造（WAAM）方法制造具有高沉积率、低设备成本的大型金属部件，以实现制造过程的形貌和力学性能，一种高精度的焊道形貌预测模型。为每道次的理想沉积建立了。

设计/方法/方法

分析了工艺参数对基于冷金属转移 (CMT) 的焊道宽度和焊道高度的动态响应。使用激光轮廓扫描仪连续捕获形态变化。使用响应面优化建立沉积珠形貌的预测模型。此外，使用 15 组二次回归分析检查模型的有效性。

发现

与实验测量值相比，预测的珠子宽度和高度的相对误差均小于 5%。然后对该模型进行必要的修改，例如进一步考虑夹层工艺参数，以指导复杂三维组件的制造。

原创性/价值

WAAMed 珠的形态预测是一个关键问题。大多数研究都集中在基于 CMT 的 WAAM 的可成形性和缺陷上，而关于工艺参数对基于 CMT 的 WAAM 中沉积层形态的影响的研究很少。为了测试加工参数对珠粒尺寸的敏感性，研究了关键参数的动态响应。建立回归模型以指导后续多层或组件沉积的工艺参数优化。