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Concept and validation of an active cooling technique to mitigate heat accumulation in WAAM

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Abstract

This work aimed at introducing and exploring the potential of a thermal management technique, named as near-immersion active cooling (NIAC), to mitigate heat accumulation in Wire + Arc Additive Manufacturing (WAAM). According to this technique concept, the preform is deposited inside a work tank that is filled with water, whose level rises while the metal layers are deposited. For validation of the NIAC technique, Al5Mg single-pass multi-layer linear walls were deposited by the CMT® process under different thermal management approaches. During depositions, the temperature history of the preforms was measured. Porosity was assessed as a means of analyzing the potential negative effect of the water cooling in the NIAC technique. The preform geometry and mechanical properties were also assessed. The results showed that the NIAC technique was efficient to mitigate heat accumulation in WAAM of aluminum. The temperature of the preforms was kept low independently of its height. There was no measurable increase in porosity with the water cooling. In addition, the wall width was virtually constant, and the anisotropy of mechanical properties tends to be reduced, characterizing a preform quality improvement. Thus, the NIAC technique offers an efficient and low-cost thermal management approach to mitigate heat accumulation in WAAM and, consequently, also to cope with the deleterious issues related to such emerging alternative of additive manufacturing.

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Acknowledgments

The authors acknowledge the Center for Research and Development of Welding Processes (Laprosolda) at Federal University of Uberlândia for the laboratorial infrastructure. The authors also thank Fronius International Gmbh, particularly Stephan Egerland, Ph.D, for kindly providing the CMT equipment used.

Funding

This study was supported by the Brazilian Coordination for the Improvement of Higher Education Personnel (CAPES), through Finance Code 001, and by the Brazilian National Council for Scientific and Technological Development (CNPq), through grants 302863/2016-8 and 315092/2018-1.

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Authors and Affiliations

  1. SENAI Innovation Institute for Manufacturing Systems and Laser Processing, Joinville, SC, Brazil

    Leandro João da Silva

  2. Laprosolda – Center for Research and Development of Welding Processes, Federal University of Uberlândia (UFU), Uberlandia, MG, Brazil

    Leandro João da Silva, Danielle Monteiro Souza, Douglas Bezerra de Araújo, Ruham Pablo Reis & Américo Scotti

  3. Department of Engineering Science, Production Technology West, Division of Welding Technology, Högström Väst (University West), Trollhattan, Sweden

    Américo Scotti

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  1. Leandro João da Silva
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  2. Danielle Monteiro Souza
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Correspondence to Leandro João da Silva.

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da Silva, L.J., Souza, D.M., de Araújo, D.B. et al. Concept and validation of an active cooling technique to mitigate heat accumulation in WAAM. Int J Adv Manuf Technol 107, 2513–2523 (2020). https://doi.org/10.1007/s00170-020-05201-4

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