Comparison of process control methods for wire-arc directed energy deposition of low carbon steels with in-situ temperature measurement

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Date

2023

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University of Texas at Austin

Abstract

Additive manufacturing (AM) techniques enable the production of near-net shape parts. Wire-arc direct energy deposition (WA-DED) can achieve a higher deposition rate among other available metal AM methods. Conventional arc welding requires a maximum interpass temperature to limit any reduction in mechanical properties, but this may not be practicable for wWA-DED. In this study, two interpass process control methods, one with maximum interpass surface temperature and the other with constant dwell time, were adopted to deposit low alloyed steel walls while maintaining the same feedstock and heat input values. Thermocouples were inserted at three different positions in the walls during deposition, to record the thermal profiles. Test samples extracted from walls exhibited similar tensile strength (~10 MPa difference) and hardness values. Microstructural evaluation showed the presence of interlayer regions with alternating coarse and fine bands of ferrite grains, irrespective of the interpass control method. These findings suggest that dwell time control is better for productivity.

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