Session: Research Posters

Paper Number: 167271

Large Scale 3d Printing of 316l Stainless Steel via Robotic Wire Arc Additive Manufacturing and Comsol Multiphysics Simulation 

Metal Additive Manufacturing (AM) has flourished as a transformative technology for manufacturing complex, large-scale metal structures with less metal waste and manufacturing time. Robotic Wire Arc Additive Manufacturing (WAAM) has gained magnificent attention because of its high deposition rate and low cost, specifically for 316L Stainless steel, which is extensively used in civilian, aerospace, and automobile industries. However, the structural finishing, integrity, and performance of WAAM-manufactured parts are highly sensitive to process parameters, such as arc stability and temperature input. This study explores the effects of variable wire arc moving speeds on the morphological and liquid bead transfer behaviors of 316L stainless steel parts during WAAM, using COMSOL Multiphysics simulations. This study contributes to providing a deeper knowledge of the relationship between process parameters and material formation characteristics in WAAM, and introduces an original framework of numerical simulation for optimizing the WAAM process via COMSOL Multiphysics.

This research methodology combines experimental and computational processes. A robotic WAAM system is implemented with wire arc scanning speed across 200 mm/min to 600 mm/min to manufacture stainless steel 316L. COMSOL Multiphysics simulates the temperature profiles, melt pool dynamics, and bead cooling behavior during the deposition. The simulation incorporates a dynamic arc heat source model, accounting for heat transfer, fluid flow, and phase change of material. This simulation model enables us to estimate the temperature gradients, solidification rates, and residual stresses, which are crucial determinants of morphological evolution and mechanical characteristics. 

In preliminary data, exceptional impact of arc scanning speed on the properties of manufactured parts is highlighted. High temperature was found with lower scanning speed (200-300 mm/min), leading to coarser bead geometry and enhanced residual stresses due to low solidification rates. Components made at 400 mm/min show less porosity and increased integrity when compared to those made at low scanning rates. This work is innovative in that it develops a dynamic arc heat source model in COMSOL Multiphysics that precisely reflects the dynamic thermal behavior of the WAAM process. This model offers a prediction tool for optimizing process parameters to get desired material qualities by combining them with the systematic modification of wire arc scanning speeds. Moreover, the combination of computational and experimental approaches provides a whole framework for grasp and enhancement of the WAAM process for 316L stainless steel.

Finally, this work investigates the possibilities of different wire arc moving speeds to improve mechanical performance and structural integrity of large-scale 316L stainless steel parts produced by robotic WAAM. COMSOL Multiphysics simulations combined with experimental validation provide vital new perspectives on process-structure connections. This work supports the existing efforts on innovative WAAM technology and makes it a practical choice for important uses in advanced production.

Presenting Author: Fardim Roney University of Louisiana at Lafayette

Presenting Author Biography: Fardim Roney is a PhD student at the Intelligent Manufacturing and Systems Laboratory of University of Louisiana at Lafayette.

Authors:

Fardim Roney University of Louisiana at Lafayette
Sen Liu University of Louisiana at Lafayette