Managing the quality of functional parts is a key challenge in wire arc additive manufacturing. In case production aluminum parts, porosity one main limitations this process. This paper provides an indicator through simulation melt pool volume First, review formation during WAAM process presented. leads to proposal article: monitoring inside produced part can be achieved monitoring. An adapted ...

Porosity is one of the most critical defects in additive manufacturing (AM). Although porosity formation significantly influenced by melt pool depth (MPD), MPD estimation and control during AM difficult to realize. In this study, a real-time system was developed reduce metal-directed energy deposition (DED). First, width, length, height, profile slope were measured using an infrared camera line...

AlSi7Mg0.6 alloy is the most widely used cast for aerospace and automotive applications. Therefore, it essential to explore effect of scanning strategy parameters on final part properties in laser powder bed fusion (L-PBF) process. The stripes chessboard strategies such as stripe length, rotation angle, island size mechanical microstructural L-PBF processed studied. evolution residual stresses ...

Metals and alloys fabricated by fusion-based additive manufacturing (AM), or 3D printing, undergo complex dynamics of melting solidification, presenting challenges to the effective control grain structure. Herein, we report on use high-intensity ultrasound that controls process solidification during AM 316L stainless steel. We find favours columnar-to-equiaxed transition, promoting formation fi...

In the present work, microstructure and corrosion behaviour of wire arc additive manufactured (WAAM) AA2024 alloy thin wall structure are investigated. Three distinctive zones in WAAM structure, including melt pool zone (MPZ), border (MPB) heat affected (HAZ). Localized initiates at multi-phase lamellar eutectic via de-alloying S-phase (Al2CuMg) intermetallics. MPB is most susceptible to locali...