Analysis on the Characteristics of Metal Droplet Transferred by Projected Transfer Mode in Wire + Arc Additive Manufacturing Process

doi:10.3901/JME.2019.03.219

Abstract

Abstract: The arc current, voltage and acoustic emission signals related to the metal droplet transfer are detected in real-time during the wire + arc additive manufacturing process, and are studied to analyze the characteristics of metal droplet transferred by projected transfer mode in DC-pulsed arc. Accordingly, a method is presented to calculate the size of droplet, arc force and droplet deposition rate in the projected transfer mode. Furthermore, the forming quality characteristics of the deposition layer are analyzed. The results show that the arc voltage, the arc current and the acoustic emission signals can be used to distinguish the droplet transfer process and the characteristics of the droplet transfer. Under the conditions of this study, the arc force increases with the increase of the arc power. The increase of the arc force will restrict the increase of the droplet size, so that the droplet size decreases and the droplet transfer frequency increases with the increase of arc power. At the same time, the increase of arc power improves the heat input and the force of spray droplet acting on the molten pool. Therefore, it is easy to cause the collapse of deposition layer, the trend of the height increasing of the deposition layer is slowed down and the microstructure of the deposition layer is obviously coarsened.

Key words: additive manufacturing, arc, arc signals, manufacturing efficiency, metal droplet transfer

CLC Number:

TG453

LUO Yi, ZHU Liang, HAN Jingtao, XU Jie, ZHANG Chengyang. Analysis on the Characteristics of Metal Droplet Transferred by Projected Transfer Mode in Wire + Arc Additive Manufacturing Process[J]. Journal of Mechanical Engineering, 2019, 55(3): 219-225.

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