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Numerical investigation of the arc properties in gas tungsten arc–based additive manufacturing

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Abstract

During gas tungsten arc–based additive manufacturing (GTA-AM), the arc is burning between a tungsten electrode and a deposited wall. With the increases in the built height, the arc behaviour becomes much different from that in gas tungsten arc welding (GTAW), in which the workpiece is keeps flat relatively. In present research, the arc properties in GTA-AM process were investigated via a numerical model including the effect of the surrounding air; the arc properties and the air transport and distribution were exhibited; the effect of the arc current on the arc properties and the air diffusion were examined. It is found that the arc is burning astride the deposited wall, altering the arc shape and peripheries significantly. A backward flow forms near the side surface of the build due to the abrupt drop of the deposited wall surface; such flow results in the air transport from the surrounding region to the inner part of the arc. Consequently, a relatively high concentration of the air occurs adjacent to the built wall, which, to a large extent, is an important reason for the oxidation and the shielding effect degradation of the layer during WAAM. In addition, the coverage of the arc plasma over the wall extends with the increased arc current surveyed, while the air diffusion towards the wall becomes intensified and its concentration presents a huge surge in this region, implying an aggravated oxidation and worsen shielding of the wall. The numerical results were in fair agreement with the experimental ones obtained by shadowgraphy technique.

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Data Availability

The datasets generated and supporting the findings of this article are obtainable from the corresponding author upon reasonable request.

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Acknowledgements

The authors are grateful to Dr. A B Murphy of CSIRO Manufacturing for providing thermophysical properties of arc plasma in gas mixture of Ar-air.

Funding

This work is supported by the China Scholarship Council (Grant no. 202108500099), National Natural Science Foundation of China (NO.51705054), and Scientific and Technological Research Program of Chongqing Municipal Education Commission (NO. KJQN202101135), and performed under the Joint Usage/Research Center on Joining and Welding, Osaka University.

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Authors and Affiliations

  1. School of Materials Science and Engineering, Chongqing University of Technology, Chongqing, 400054, China

    Xinxin Wang, Jia Zhang, Ying Deng & Dawei Chen

  2. Chongqing Municipal Engineering Research Centre of Higher Education Institutions for Special Welding Materials and Technology, Chongqing, 400054, China

    Xinxin Wang

  3. Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka, 567-0047, Japan

    Xinxin Wang, Ngoc Quang Trinh, Shinichi Tashiro & Manabu Tanaka

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  1. Xinxin Wang
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Correspondence to Xinxin Wang.

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The paper (DOC. XII-2526–2022) was recommended for submitting to the Welding in the World for publication in IIW 2022.

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Wang, X., Zhang, J., Deng, Y. et al. Numerical investigation of the arc properties in gas tungsten arc–based additive manufacturing. Weld World 67, 945–954 (2023). https://doi.org/10.1007/s40194-023-01473-y

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