Physically based bead topology model coupled with electro-mechanical power source model applied for wire and arc additive manufacturing

Abstract

The present work is carried out in the framework of the WAS project [1] which deals with WAAM process. The process relies on an automatized welding process in which a part is built by successively deposed metal bead. We propose a physically based bead topology model using the equilibrium between the hydrostatic pressure and the capillarity force, under twodimensional hypothesis. This equilibrium can be described by the Laplace equation [2]. The proposed model is used to estimate a bead topology which is deposed on an inclined support. Moreover, a deposed melted metal volume is necessary for the bead topology model. By modelling a gas metal arc welding (GMAW) power source system [3], the volume can be estimated and be used as a physical parameter for the bead topology model. Combining the topology and the power source models, the coupling model allows to simulate the topology of a weld bead through WAAM. In addition to the modelling, experimental profiles of the beads are used to validate the model.

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