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Simulation Study on Temperature and Stress Fields in Mg-Gd-Y-Zn-Zr Alloy during CMT Additive Manufacturing Process
Mingkun Zhao1, Zhanyong Zhao1, Wenbo Du2
1School of Materials Science and Engineering, North University of China, Taiyuan 030051, China.
Materials (Basel, Switzerland)
|March 13, 2024
Summary
Researchers optimized heat sources for additive manufacturing of Mg-Gd-Y-Zn-Zr alloy using cold metal transfer (CMT). Optimal speeds minimize thermal accumulation and residual stress, enhancing material properties.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Metallurgy
Background:
- Additive manufacturing (AM) of magnesium alloys presents challenges in controlling thermal profiles and residual stresses.
- Cold Metal Transfer (CMT) is a promising arc welding process for AM applications, but requires optimized heat source parameters.
- Mg-Gd-Y-Zn-Zr alloys are of interest for lightweight structural applications, demanding precise processing for optimal performance.
Purpose of the Study:
- To develop and analyze a novel heat source combination for CMT wire-arc additive manufacturing of Mg-Gd-Y-Zn-Zr alloy.
- To investigate the effects of process parameters on temperature distribution and residual stress.
- To correlate microstructural features and mechanical properties with process-induced stresses.
Main Methods:
- Development of a hybrid heat source model combining uniform body and tilted double ellipsoidal sources.
- Finite element analysis (FEA) simulations to predict temperature fields and stress distributions.
- Experimental validation using Electron Backscatter Diffraction (EBSD) and microhardness testing.
Main Results:
- Optimal feeding and welding speeds of 8 m/min and 8 mm/s were identified, minimizing thermal accumulation and residual stress.
- Z-axis residual stress was found to be the dominant stress component.
- EBSD revealed weak texture, while KAM analysis indicated highest residual stress in the 1st layer, with the 11th layer exhibiting higher stress than the 6th.
- Microhardness variations correlated with residual stress and dislocation density, with higher stress leading to increased microhardness.
Conclusions:
- The developed heat source combination and optimized parameters effectively control thermal accumulation and residual stress in CMT AM of Mg-Gd-Y-Zn-Zr alloy.
- Residual stress significantly influences the microstructure and microhardness of the manufactured components.
- Simulation results demonstrated high consistency with experimental findings, validating the predictive capability of the model.
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