A thermo-capillary-gravity model for geometrical analysis of single-bead wire and arc additive manufacturing (WAAM)

摘要

A physically based model is developed to predict deposit profiles during wire and arc additive manufacturing (WAAM). The model takes material properties and process parameters as input, determines the amount of melt and its penetration component through a thermal analysis, and calculates the layer and bead geometries through a capillary-gravity analysis. While none of the model parameters and constants is adjusted by fitting to the experiments, it can well predict the layer height and width of walls manufactured from a grade of mild steel at various conditions. The model is claimed to be valid for a wide range of materials and conditions, even with very heavy deposited beads. The outputs are calculated from basic geometrical features such as bead curvature and contact and penetration angles. Hence, the presented model can help in understanding the effects of process parameters on the geometry of the layers. The inter-layer temperature, the travel speed, the wire feed speed, and the heat input are analyzed, accordingly.