A dataset for "Characterizing power output, thermal evolution, and bead geometry in wire arc additive manufacturing under power-regulated arc control"
Description
This study investigates the influence of power and wire feed speed (WFS) settings on power output, thermal conditions, and geometric outcomes in wire-arc DED under constant-power control. Unlike conventional wire-arc DED setups which employ constant-voltage or constant-current settings, the constant-power setting introduces dynamic process behavior which has been underexplored in existing literature. Through 9 multi-bead, multi-layer builds and 49 single-bead experiments, the effects of the power and WFS settings on the measured output power are investigated, as well as how these parameters, in turn, influence mid-process bead heights, build temperatures, and substrate temperatures. Additionally, the evolution of the build’s interpass temperature and several substrate locations’ temperatures are tracked, and the varying relationships between these temperatures are assessed throughout the builds’ progression. The study’s breadth of experiments enables a statistically grounded exploration of heat accumulation and bead geometry formation for a unique power control mode, under realistic wire-arc DED conditions. Dataset information: - Study_parameters.jpg gives the 9 multi-layer builds' WFS and power settings. - P_output_analysis_data.csv gives the data for the analysis of the system's output power values and their deviations from the power setting, based on various WFS and power settings for single beads. - build_heights_dict.npy & bead_heights_dict.npy give the build and individual bead height values at each "image point" (the X-Y coordinates of the torch when an individual IR image was taken). These Numpy files contain python dictionaries with all of the build and bead height data for all 9 of the multi-layer experiments. The keys in the dictionaries are based on the experiment and layer numbers, and each key's value is a 6x120 array-- 6 beads x 120 image points going across each bead. The 120 image points' height values are in order from -X to +X, not in the order in which all of the beads were deposited. The 6 beads are in the order in which they were deposited-- +Y to -Y. - Each experiment's "mean_temps_whole_experiment.npy" file includes an 8x6x140x720 Numpy array. The 1st & 2nd dimensions represent the experiment's 8 layers & 6 beads. The 140-dimension represents the 120 images which were taken during each bead, plus the 10 images from before & after that bead's deposition, and they are listed in order. The 720-dimension represents the total number of image point locations (incl. all 6 beads) which are present on the current layer. - The "mean_temps_substrate_locations.npy" files each include a 8x6x140x8 array. The last dimension of this array represents the temperatures of 8 locations on the substrate's top surface. Substrate_locations.png gives the coordinates of these locations on the substrate, relative to the origin which is set at the -X, -Y top corner of the substrate plate.
Files
Steps to reproduce
- The nine multi-bead, multi-layer builds were constructed using a robot WAAM system which included a Lincoln Electric MIG Power Wave R450 power source, a Tormach ZA06 industrial robot arm, a Tormach 1100MX CNC enclosure, and a Dayton Welding Fume Extractor. The 49 single beads were deposited using a Cincinnati Dart 500 CNC enclosure retrofit with a welding torch and a Lincoln Electric Power Wave S500 power source. - All of the builds were created using mild steel alloy LI SuperArc L-59 MIG wire with a diameter of 1.1 mm, mild steel 152.4 x 76.2 x 12.7 mm substrate plates, and a combination 98% Argon / 2% CO2 shielding gas with a flow rate of 25 CFH. The contact tip to work distance (CTWD) was 10 mm for the first layer of each build, and varied for the multi-layer builds' later layers. The traverse speed was set to 3.4 mm/second, and Lincoln Electric's constant-power control mode (Mode 40) was used. - The 9 multi-bead, multi-layer builds were constructed using 3 different WFS values and 3 different power settings. Their individual WFS and power settings are listed in the file Study_parameters.jpg. All of these builds were 6 parallel beads across and 8 layers tall. A horizontal stepover distance between the beads of 2.7 mm, as well as a 180-second dwell time between layers were also used. The beads were deposited along the +X and -X directions, with the bead at the highest Y value being deposited first in each layer (starting at 25.4 mm X, 50.8 mm Y), going in the +X direction, and with each bead after that reversing direction. All of the layers used the same bead deposition pattern. - Temperature data was collected throughout the multi-layer builds by collecting IR images at 4 Hz using a FLIR A700 camera with a resolution of 640 x 480 pixels, or 0.48 mm/pixel from its mounted position, and a temperature accuracy of +/-2°C within the 0-650 °C range. The camera was thermally calibrated using a blackbody furnace, and an assumed-constant material emissivity value of 0.95, selected based on thermocouple testing, was applied. - Build geometry data was collected during the multi-layer builds by taking 3D geometry scans of the substrate and build surface using a FARO laser line scanner connected to a FARO QuantumM ScanArm and tripod base, before each build, as well as after each layer. While sufficient data was collected of the front, top, and edges of the builds to accurately calculate the build heights, the back of the builds (the +Y side) were not able to be scanned. This laser line scanner provides a 0.025mm scan resolution, and the laser scans are collected using Geomagic Control X 2022 software. The build height values are each the mean value of the laser scan points which are within 0.75 mm in X & Y from the image point's X-Y coordinates. The bead height values are the differences between the layers' build height values.
Institutions
- Georgia Institute of TechnologyGA, Atlanta
Categories
Funders
- National Nuclear Security AdministrationDistrict of Columbia, United States