Mathematical modelling of formation process for multi-layer 3D structure produced by additive method using arc heat sources

Abstract

The results of modelling of temperature fields, kinetics of deposition of layers of dissimilar metals and nature of structural transformations in formation of multi-layer structure of 17G1S and 30KhGS steels are presented. Computer modelling was performed using COMSOL Multiphysics software package. The work takes into account effect of temperature on thermal and physical parameters of steels. To increase productivity of additive process the work has studied simultaneous effect of 3 arcs on process of deposit formation, kinetics of structural transformations and diffusion processes of alloying elements redistribution. The calculations show that preheating of the substrate by arc in the beginning of the process before application of deposited material is necessary in order to decrease a stress level between additive deposit and substrate to 50 MPa. It is shown that the time of passing between neighbor arc heat sources shall be kept in 5- 30 s range. It is determined that low power of arc (1 kW) mainly provokes formation of ferrite-bainite structure in the deposit, portion of bainite in which makes 71 %, ferrite 28% and martensite ~ 1%. Application of larger power arc (5 kW) forms in the deposit bainite-martensite structure, portion of bainite in which makes ~ 50%, portion of martensite rises up to 40% and that of ferrite to 10%. Increase of arc power results in rise of maximum temperature of liquid pool to 1750-1850 °C, growth of cooling rate to 15 – 25 °C/s , and, as a consequence, increase of martensite portion in the structure of deposited layers.

Keywords

• additive manufacturing
• modelling
• deposition
• functional materials
• structural transformations
• microstructure