Determination and effect of cold metal transfer parameters on Ti6Al4V multi-layer deposit during wire arc additive manufacturing

• Published in: Welding in the world Vol. 67; no. 7; pp. 1629 - 1642
• Main Authors: Reyes-Gordillo, Emmanuel, Gómez-Ortega, Arturo, Morales-Estrella, Ricardo, Pérez-Barrera, James, Gonzalez-Carmona, Juan Manuel, Escudero-García, Ramiro, Alvarado-Orozco, Juan Manuel
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01-07-2023; Springer Nature B.V
• Subjects: Additive manufacturing; Arc deposition; Aspect ratio; Chemical composition; Chemistry and Materials Science; Deposits; Dilution; Hardness measurement; Manufacturing; Materials Science; Metallic Materials; Metallurgy; Microhardness; Multilayers; Overheating; Parameters; Research Paper; Solid Mechanics; Substrates; Theoretical and Applied Mechanics; Thin walls; Titanium base alloys; Wire; Process optimization; Cold metal transfer; Wire arc additive manufacturing; Ti6Al4V; Layer continuity
• ISSN: 0043-2288; 1878-6669
• DOI: 10.1007/s40194-023-01511-9

This study was developed to determine the parameters of the cold metal transfer process for the Ti6Al4V multi-layer deposits. Also, the influence of the heat supplied on the geometry of the walls, the chemical composition, and microhardness of the wire arc additive manufacturing of Ti6Al4V multi-layer deposits was analyzed. An experimental methodology was established to define the process factors focusing on the morphological aspects on deposited beads. Differential scanning calorimetry showed that the maximum working temperature for Ti6Al4V multi-layer deposits and substrate plate was about 450 °C and 550 °C, respectively. The experimental results showed overheating above 450 °C, which is the maximum recommended working temperature for Ti6Al4V, in the four previous layers during processing. An aspect ratio of 1.5 and metallurgical dilution of 20% were optimum for obtaining continuous thin walls for both single and multi-layer deposits. Furthermore, a continuity factor along the construction walls was defined, by 3D measurements, as 1.90 when taking into account all deposited layers. In addition, it was observed that the oxygen concentration on the walls rises with increasing power regardless of the interpass time used. Finally, microhardness measurement values showed more dispersion when the limit values of supplied heat were evaluated.