A dataset for "A high-performance WAAM process for Al-Mg-Mn using controlled short-circuiting metal transfer at increased wire feed rate and increased travel speed"
In the study, a high-performance controlled short-circuiting metal transfer process at a wire feed rate of 12 m/min for WAAM with an Al-Mg-Mn alloying system was developed. The arc current and voltage waveforms were studied by oscillograms processing and then modified to reduce energy input in comparison with a self-regulated gas metal arc welding process. The newly developed process was implemented in manufacturing of the sample parts at a travel speed of up to 150 cm/min. Modified waveforms in a combination with an increased travel speed led to a decrease in heat input, which appeared to be 16% lower than that of a conventional self-regulated process. Decreased heat input lead to an improvement of the geometry preservation stability at high process rates (up to 2.2 kg/h). The mechanical properties study showed that the elongation of the tensile samples was up to 41%, the increase in elongation was explained through macro- and microstructure analysis. The provided data shows remarkable tensile test results and remarkable macro- and microstructure images, which were used to evaluate porosity and grain size in the study of the deposited metal properties. High-speed video of a metal transfer during deposition using the newly developed process along with a high-speed video of a wire feeding process are also presented in this dataset.
Steps to reproduce
Walls were produced on a 5056 aluminium alloy substrate with a size of 350*350*40 mm. ESAB OK Autrod 18.22 was used as an Al-Mg-Mn alloy wire with a diameter of 1.2 mm. The WAAM system was composed of a Yaskawa Motoman MH24 robot and a EWM Alpha Q 552 welding power source. A developed high-performance controlled short-circuiting metal transfer process at a wire feed rate of 12 m/min for WAAM with an Al-Mg-Mn alloying system was used to print walls. Argon of 99.99% purity was used as a shielding gas. Tensile tests were carried out on a Tinius Olsen H25KT machine, tensile samples were cut from walls in OX and OZ directions and from bricks – in OX, OY, and OZ directions. The preparation of cylindrical samples with a diameter of 3 mm and a length of 15 mm was carried out in accordance with GOST 6996-66. Longitudinal (ZOX) and transverse (ZOY) sections of walls were prepared using the Buehler grinding system. Macro- and microstructure images were obtained using a Leica DMI 5000M metallographic microscope.